1. ~ vi ~
Internship Report
A A D H U N I K G L O B A L
E N E R G Y
C / o T I N Y T E C H P L A N T S
P V T . L T D .
T a g o r e R o a d , R a j k o t 0 2
0 2 8 1 2 4 8 0 1 6 6
t i n y t e c h @ t i n y t e c h i n d i a . c o m
0 6 - M a y - 1 3
NIRAV REGE
MEDA HEMANTH KUMAR
A K MAHESH
Dissertation Submitted for the partial awarding of the
certificate for the Certified Nuclear Engineering Professional
Program at PM Dimensions Pvt. Ltd. Internship period is from
5th March, 2013 to 5th May, 2013.

2. ~ i ~
Index
1. Participating Interns ii
2. Introduction to the Company iii
3. Acknowledgements iv
4. List of Figures v
5. List of Tables vi
6. Scope of Study
a. Solar Parabolic Cooker 1
b. Solar Funnel Cooker 3
c. Boilers 6
d. Steam Engines 10
e. Steam Power Plant 12
f. Solar Power Plant Using Solar Concentrator 13
g. Solar Oven 15
h. Scheffler Reflector 16
i. Biogas Plant 18
j. Steam Engine Operated Water Pump 20
k. Pedal Operated Grain Mill 21
l. Wind Mills 22
m. Other areas 25
7. References 30

3. ~ ii ~
Participating Interns
Nirav Rege
BE (Electrical)
CNEP – 11/6
Meda Hemanth Kumar
B Tech (Electronics & Communication)
CNEP – 11/5
A K Mahesh
B Tech (Electronics & Communication)
CNEP – 13/2

4. ~ iii ~
Introduction to the Company –
Aadhunik Global Energy
C/o TinyTech Plants Pvt. Ltd.
A Private Limited Company based in Rajkot, Gujarat is a very popular company in
emerging countries as the manufacturer of unconventional products i.e.
miniature versions of various machines for cost reduction and self-reliance.
The company working for promoting tiny enterprises in various industrial fields,
through human technology for rural development, local self-reliance, poverty
eradication, exploitation removal, employment and income generation by
breaking company centered economy & promoting family centered economy all
over the world.
The company is a manufacturer of solar cookers, solar concentrators, biogas
plants, wind turbines and steam engines, just to name a few in the energy sector.
Apart from these they have oil mill, oil refinery fruit and vegetable processing
machines and many more.
The founder, Mr. V. K. Desai is a mechanical engineer and law graduate. He is 72
years “young”. As he was born in poor farmer's family and as is deeply influenced
by Mahatma Gandhi's life, his heart always burns for poor, oppressed and
trodden people. In 1982, he founded TINYTECH PLANTS and since then he is
deeply engrossed in development of small and simple technology for creating and
strengthening local economy. He now finds support in his son, Mr. Gopal Desai
who is also a mechanical engineer and started working under his father while
studying engineering.

5. ~ iv ~
Acknowledgements
Success is the manifestation of perseverance, inspiration and motivation. Apart
from the efforts of the interns, the success of any project depends largely on the
encouragement and guidelines of many others. We take this opportunity to
express our gratitude to the people who have been instrumental in the successful
completion of this amazing learning experience.
We attribute our success of this experience to our guide, Mr. V. K. Desai, whose
endeavor for perfection, enthusiasm, foresight and innovation contributed in a
big way not only in providing practical technical experience but also sharing his
views on socio economic conditions of our country. His constant insistence on
providing simple technology to the rural and backward people has opened new
avenues for decentralizing big industries to small scale industries.
We are also indebted to the supervisors, Mr. Jhikubhai and Mr. Rajubhai and the
entire staff of Tinytech Plants for extending a warm welcome and providing a
great atmosphere for us during our 2 month stint here. A special thanks to Mr.
and Mrs. Suhas Dole for accommodating us at their residence with big hearts and
taking care of our meals day in and day out. We are indeed indebted to all of
them.
The guidance and support received from all the members who contributed to this
experience was vital for the success of the internship. We are grateful for their
constant support and help.

6. ~ v ~
List of Figures
Fig 1: Domestic Parabolic Solar Cooker
Fig 2: Community Parabolic Solar Cooker
Fig 3: Focal Point Graph
Fig 4: Design Solar Funnel Cooker
Fig 5: Corrugated Polypropylene Sheets
Fig 6: Marking Of Polypropylene Sheets
Fig 7: Affixing Aluminum Foils & Indenting
Fig 8: Assembling
Fig 9: Dimensions
Fig 10: Yarrow Type Boiler Outline
Fig 11: Yarrow Type Boiler Front View
Fig 12: Fire Tube Boiler
Fig 13: Fire Tube Boiler Spark Arrester
Fig 14: Mono Tube Boiler
Fig 15: Spark Arrester
Fig 16: Safety Relief Valve
Fig 17: Pressure Gauge
Fig 18:Centrifugal Water Separator
Fig 19: Water Level Indicator
Fig 20: Displacement Lubricator
Fig 21: Working Principle
Fig 22: Array of Steam Engines
Fig 23: Boiler Connected With Steam Engine
Fig 24: Generator
Fig 25: Solar Concentrator
Fig 26: Array of Reflectors
Fig 27: New Design
Fig 28: Ball Socket Joint
Fig 29: Solar Oven
Fig 30: Scheffler Working Principle
Fig 31: Sun Tracking Devices
Fig 32: Application of Scheffler
Fig 33: Bio-Gas Plant Design
Fig 34: Bio-Gas Plant
Fig 35: Design - Steam Engine Operated Water
Pump
Fig 36: Components - Pedal Operated Grain Mill
Fig 37: Assembled Pedal Operated Grain Mill
Fig 38: Working Model
Fig 39: Wind Mill VIRYA 1.04
Fig 40: Mango Pulp Machine
Fig 41: Banana Wafer Plant
Fig 42: Coconut Grinding Machine
Fig 43: Oil Refinery
Fig 44: Oil Mill
Fig 45: Potato Wafer Plant
Fig 46: Popcorn Machine
Fig 47: Surgical Equipment’s
Fig 48: Railing Components
Fig 49: Pipe Clamps
Fig 50: Induction Motors
Fig 51: Domestic Grain Mill (Automatic)
Fig 52: Sugarcane Crushing Machine
Fig 53: Manually Operated Air Blower
Fig 54: Powder Coating Procedure
Fig 55: Aluminum Products
Fig 56: Pipe Drawing
Fig 57: Rolling For Packaging
Fig 58: Raw Material (Plastic)
Fig 59: Molten Iron from the Furnace
Fig 60: Pouring The Molten Iron Into The Dye.
Fig 61: Piston Rod Assembly

7. ~ vi ~
List of Tables
Table1: Focal Point Calculation
Table 2: Experiment 1
Table 3: Experiment 2
Table 4: Capacity of Yarrow Type Boilers
Table 5: Models of Steam Engines
Table 6: Specification of Scheffler
Table 7: Specifications of VIRYA 1.04

8. ~ 1 ~
Parabolic Solar Cooker
Purpose: - To replace the existing cooking fuels, like LPG, Kerosene, fire wood, charcoal, etc.
with solar energy, which is a renewable source of energy. The sun is supplying free and
ecofriendly energy and this device was designed to harness it.
Design: - The reflecting surface is a parabolic square shaped with a folding design. It comes in
two sizes.
• The domestic solar cooker has a supporting stand made of rectangular pipes of 40 mm x
20 mm cross section. Reflector sheets are square anodized aluminum sheets of 1.2 m x
1.2 m and its frame is made of 2 parabolic strips and 7 parabolic round bars.
Fig 1: Domestic Parabolic Solar Cooker
• The community solar cooker has a supporting stand made of rectangular pipes of 40 mm
x 20 mm cross section. Reflector sheets are square anodized aluminum sheets of 1.5 m x
2 m.
Fig 2: Community parabolic Solar Coooker
Principle: - The working principle of the parabolic solar cooker is based upon the focal point of
the parabola. Once focused, the entire incident sunrays are reflected at the focal point.

9. ~ 2 ~
Installation: - The parabolic solar cooker is assembled using nuts and bolts and after erection of
the stand, the reflecting anodized aluminum sheets are tied to the horizontal cross bars to
obtain a parabolic shape.
Operation: - Once installed, the reflecting faces are sun, and the focused with the help of the
focal bolts placed on the hangar pipe of the reflector. The shadow of the bolt head should be in
the center. Once focused, place the cooking vessel on the focal stand and start cooking.
Calculation: - The parabolic curve is calculated using the equation for parabola.
y = x2
/4f
Where, x and y are the coordinate axis and f is the focal point.
For the domestic solar cooker, the focal point is 420 mm.
x (mm) y (mm)
100 6
200 24
300 54
400 95
500 149
600 214
Table 1: Focal Point Calculation
Figure 3: Focal Point Graph
Capacity: -
• Domestic: - Can cook for 10 to 20 people in 30 to 40 minutes.
• Community: - Can cook for 30 to 40 people. 19 kg of rice (dry rice 5kg +14kg water =
cooked rice 19 kg) can be cooked in 60 minutes. In an average day from 9:00am to
5:00pm, about 100 to 120 kg of rice can be cooked.
Applications: - Mid day meals in schools, hostels, hotels, restaurants, hospitals, offices, small
factories, home scale cooking related small business, clubs, associations, communities, refugee
camps, etc.
Advantages: - Cheap, ecofriendly, portable, foldable, easy to install, light weight, easy to
transport, low payback period, no running costs, no maintenance required.
Disadvantages: - Seasonal, weather dependent, Time required is more as compared to other
sources.
600, 214
0
100
200
300
0 200 400 600 800
AxisTitle
Axis Title
Parabola
Parabola

10. ~ 3 ~
Solar Funnel Cooker
Purpose: - With the availability of various cookers in the market, viz. pressure cooker, electric
cookers, steam cookers and solar cookers, which do not come cheap, the solar funnel cookers is
a revolutionary cheap substitute for the aforesaid cookers.
Design: - The cooker can be constructed, in less than an hour, using corrugated polypropylene
sheets with 5 mm thickness, aluminum foil sheet with 0.1 mm thickness. The plan and the
construction steps for the Sun-Funnel cooker are as shown below.
Fig 4: Design Solar Funnel Cooker
Step 1 - Obtain two pieces of corrugated polypropylene sheets. Cut them to the dimensions as
specified in the plan.
Fig 5: Corrugated Polypropylene Sheets
Step 2 – Mark the lines using a specially devised stencil for faster work, according to the plan
and use a metal indent the fold lines with a straight edge.
Fig 6: Marking of polypropylene sheets

11. ~ 4 ~
Step 3 – On the surface of the corrugated polypropylene sheets, affix the aluminum foil sheet
without any wrinkles for perfect reflection.
Fig 7: Affixing aluminum foils and indenting
Step 4 - Bend the two prepared pieces to form two L-shaped panels. Join the two L-shaped
panels together, as shown in the photo below, using adhesive tape. Also cut 25 cm on the
bottom surface of the funnel so as to maintain the angle of the vessel while shifting the cooker
for focusing.
Fig 8: Assembling
Principle: - A deviation of parabolic cooker, it also works on the principle of the parabola, but
with the square edges, the focal point is spread onto a surface, i.e. the entire vessel is focused
upon. The black colored powder coated vessel is packed into high density plastic bag (no
leakage) to trap the heat and for the uniform heating. The distance of the top opposite edges
should be approx. 85 cm.
Calculation: - For the bending angles of the metal strip
In a right triangle angle,
Sin α = opposite/hypotenuse
Cos α = adjacent/hypotenuse
Tan α = opposite/adjacent
For α, Hypotenuse = 300 mm, Opposite = 230 mm, Adjacent = 200 mm
α = Sin-1
(230/300) = 50o
α1 = 180 – (50 + 90) = 40o

12. ~ 5 ~
Fig 9: Dimensions
For β, Hypotenuse = 300 mm, Opposite = 95 mm, Adjacent = 315 mm
β = Sin-1
(95/300) = 18.5
β1 = 180- (90 + 18.5) = 71.5o
The frame has been designed using these calculations.
Experiments: - Observation for 4 items
Experiment 1: - Rice Boiling
Days Weight of
rice
Weight of
water
Weight of
vessel
Weight
after
cooking
Time
(H:MM)
Result
1 100 g 300 ml 450 g 800 g 1:30 Boiled
2 300 g 700 ml 450 g 1450 g 1:50 Boiled
3 600 g 1500 l 600 g 2200 g 2:30 Boiled
Table 2: Experiment 1
Experiment 2: - 4 items
Cooker
No.
Items Preparation Weight Observation 1
(Time)
Observation 2
(Time)
Result
1 Rice Boiling 600 g of rice +
1.5 l of water
2:00 2:30 Boiled
2 Potato Boiling 1 kg 1:30 2:30 Not Boiled
3 Cake Baking 800 g dough 1:00 1:30 Baked
4 Peanut Roasting 550 g 0:30 2:30 Roasted
Table 3: Experiment 2
Advantages: - Cheap, Portable, Foldable, Long life, easy to install.
Disadvantages: - Little more time required as compared to Parabolic Cooker for cooking.
Our additional inputs: - For a perfect parabolic shape of the funnel and to maintain it at 85 cm
as per design, addition of a metal strip clipped to the frontal opening of the cooker.

13. ~ 6 ~
Boilers
Purpose: - The main purpose of any boiler in the energy sector is to generate steam using
various fuels like, coal in thermal power plant, uranium in nuclear power plant, gas in gas power
plants, etc.
Design: - Of the many types of boilers present, we will discuss only 3 types,
1. Water-tube (Yarrow type) boiler
This type has three drums in a delta formation connected by water tubes and is
generally biomass-fired. Due to its three drums, the Yarrow boiler has a greater water
capacity. It includes economizer and super heater, test pressure 300 – 400 psi, working
pressure 150 - 160 psi complete with water level gauge set, pressure gauge, safety
valve, fire grates and 20ft chimney 1 set+ interconnecting pipe lines, valves, pipe fittings
etc. Boiler is insulated with cerawool.
Fig 10: Yarrow type outline Fig 11: Yarrow Type Boiler Front View
2. Fire-tube boiler
This type of boiler is a one-pass boiler with the furnace at the bottom and tubes running
between the lower and upper tube sheets. The furnace can be enclosed on its sides with
a water cooled jacket or it may be made up of masonry. The top tube sheet in a steam
boiler can be above or below the water line. When it is above, it is called a dry-top and
when it is below, it is called a wet-top. A vertical boiler has a small "footprint" and can
be installed in boiler rooms with limited space.
Fig 12: Fire tube boiler Fig 13: Fire tube boiler spark arrestor

14. ~ 7 ~
3. Mono-tube boiler
The mono-tube boiler is a typical kind of heat exchanger. It consists of a large pipe with
a tube helically placed on its inner surface. The heat source flows through the pipe and
hence heats the water in the helical tube to generate steam. This was designed
particularly for the jaggery industry, where the sugarcane juice is boiled for a long time
until it attains a particular consistency. The fuel used for boiling the sugarcane juice is
biomass (sugarcane molasses). A large amount of heat is required and is generated. The
smoke coming from the burning of the sugarcane molasses contains a large amount
heat. This heat is introduced into the mono-tube boiler and heat is exchanged to
generate the steam. This steam is then used for various purposes like electricity
generation, operating the sugarcane juice extractor, etc.
Fig 14: Mono-tube boiler
Peripheral Components of boilers: -
a. Spark Arrestor: - In order to avoid the spark to enter the chimney, a box comprising of
the spark arrestor, is placed between the boiler top and the chimney inlet. It comprises
of a pair of U-bends (Effectively an N-bend) which arrests the spark. As the hot smoke
coming from burning of the biomass has the ability to change direction of flow, it flows
through the spark arrestor into the chimney, leaving the sparks and other heavy un-
burnt particles to be arrested in the spark arrestor. Only used in Yarrow type boiler.
Fig 15: Spark Arrestor Fig 16: Safety Relief Valve Fig 17: Pressure gauge

15. ~ 8 ~
b. Pressure Gauge: - The measurement of the pressure in the main header of the boiler is
done by the pressure gauge. It is tested by hydraulic machine up to 600 psi but its
working pressure is about 150 psi.
c. Safety Relief Valve: - The boiler is designed to work under a certain pressure. In case of
higher pressure in the main header, the safety relief valve opens and discharges the
steam into the atmosphere. It operates on the design of a spring. In case of high
pressure, the spring is compressed and the pressure is dropped. As the pressure is
controlled into the working range, the spring is released and the valve is closed. Thus,
the safety relief valve is an automatic operating safety device.
d. Centrifugal Water Separator: - To achieve dry steam, a centrifugal water separator is
connected to the outlet of the steam. It comprises of a helical pipe from the top to
bottom and a straight pipe from the bottom to top in the center. The steam inlet is
tangential to the cylindrical centrifugal water separator. The steam having an ability
change its direction rapidly comes up from the straight pipe to the outlet leaving he
condensed water and moisture at the bottom, which is periodically removed.
e. Water Level Indicator: - It is very important to maintain the water level in the boiler in
order to avoid any damage to the tube-sheets due to overheating. In case of lower level
of water, more water is pumped into the boiler. Its range is 25% to 75 %.
Fig 18: Centrifugal Water Separator Fig 19: Water level indicator Fig 20: Displacement Lubricator
f. Displacement lubricator: - The valve cylinder and the piston require oil for the smooth
running of the motor. The lubrication removes any chance of damage or heat
production in the valve cylinder and the main cylinder. For this purpose the lubricator is
used. A part of the steam is passed through the displacement lubricator, where the
steam is condensed into water. Due to the density of oil being more than water, it floats
on the water and moves up. This oil is then mixed with the steam going into the valve
cylinder.
g. Super-heater: - It elevates the temperature of the steam produced in the boiler further
for form the dry steam. It is main header, connected to the bottom headers.
h. Cerawool insulator: - In order to insulate the boiler, i.e. to not allow the heat generated
to leak outside the boiler, the entire boiler is coated with cerawool insulator from the
inside (except bottom).

16. ~ 9 ~
The Capacity for various models for yarrow type boilers: -
Heating Area (feet2
) Test Pressure (psi) Working Pressure (psi) Chimney Height (feet)
140 400 160 20
100 400 160 20
90 300 150 20
83 300 150 20
54 300 150 20
Table 4: Capacity of Yarrow Type Boilers
Drawbacks: - Manual feeding of biomass required, burning of biomass emits smoke, operator
required.

17. ~ 10 ~
Steam Engine
Purpose: - To convert the heat energy of the pressurized steam into mechanical energy.
Design: - A steam engine has a piston that moves when pressure is applied, and valves to
control the intake and exhaust of the contents of the cylinder. The inlet valve opens, and steam
under pressure pushes on the piston, until you open the exhaust valve to let it out.
Fig 21: Working Principle
Principle: - When force is applied to the object in such a manner as to cause the object to
move, work is performed. If the object does not move, no work is performed, no matter how
long the applied force may be. Steam admitted behind the piston in the steam engine causes
the piston to move. Hence, steam performs work upon the piston. The amount of work
performed is always equal to the force applied multiplied by the distance through the object
moves. The unit of work is kg-m.
Working: - As the steam is introduced into the valve cylinder, the piston valve is pushed down
due to the high pressure. Due to the eccentricity, the rotor shaft is rotated by 180o
. The steam
then enters the main cylinder and pushes the main piston up thereby rotating the shaft by
another 180o
in the same direction completing 1 full rotation. It also brings back the piston
valve back to its position. The crank shaft follows the eccentricity by an angle of 53o
. By
adjusting the angle between the crank and eccentricity, it can be rotated in clockwise (-53o
) or
anti-clockwise (+53o
) direction. The same process is repeated and a continuous rotational
output is achieved. In order to achieve this process smoothly, we need to lubricate the surfaces
using lubricating oil. Thus, the steam engine is equipped with a hand operated lubricating
pump. This oil, when pumped, enters the valve cylinder. A pulley cum flywheel is present on the
rotor shaft for connecting the load.

18. ~ 11 ~
Fig 22: Array of Steam Engines
Available models: -
Power
(HP)
Cylinder type Cylinder dia
(inch)
Stroke length
(inch)
Pulley dia
(inch)
Weight (kg)
2 Single 2 3 14 35
5 Single 3 4 12 85
8 Single 4 4 16 100
10 Double 3 4 10 130
18 Single 4.5 6 16 200
Table 5: Models of Steam Engines
Applications: - Water pumping, Rice milling, oil milling, sugarcane crushing, power generation,
cotton ginning, grain grinding, etc.
Advantages: - Simple design, easy to operate, cost effective, No running cost, environment
friendly.
Disadvantages: - Boiler required, time consuming startup, routine maintenance required, more
space required.

19. ~ 12 ~
Steam Power Plant
Purpose: - Steam power plant is used for rural electrification of village and community.
Wherever enough wood or biomass is available or where biomass is generated from process
itself, tiny steam power plants are ideally suitable.
Design: - A steam Power Plant consists of steam engine, boiler and generator. The boiler
produces steam; the steam engine converts the heat energy of the pressurized steam into
mechanical energy. This mechanical (rotational) energy is converted into electric energy by the
generator.
Fig 23: Boiler connected with the Steam Engine Fig 24: Generator
Advantages: - Localized electrification, cheap power, can be used instead of diesel generators.
Disadvantages: - Operator required, cannot be connected to the grid.

20. ~ 13 ~
Solar Thermal Power Plants using Solar Concentrator
Purpose: - To generate enormous amount of heat, enough to heat the thermic oil and generate
steam in the heat exchanger, or directly generate steam in the focal boiler.
Design: - The freznel type solar thermal power plant will consist of series of mirror reflectors of
dimensions 90 cm x 20 cm each, with manual sun tracking. At focal point, there will be heat
receiver where thermic oil will be heated which will go to heat exchanger to produce steam
which will run steam engine which can be directly connected to various machines. Steam
engine can also drive alternator to produce electricity. For 1 KW power, maximum 20 m2
reflectors are required.
Fig 25: Solar Concentrator
Working: - The solar concentrator works on the principle of focusing the sunrays at a common
focal point by the means of reflection. The solar concentrator spreads to about 110 m2
with 500
reflectors. The concentrator will have to be focused after some time to keep it focused at the
focal point. This is done manually or by adopting a sun tracking mechanism. Once the
appropriate heat is generated, and the thermic oil is heated, the heat exchanger produces
steam to operate steam engines. The generator will be coupled with the steam engine and
electricity cam be generated.
Defect in original design: - Unable to tilt the mirror in the horizontal (north – south) direction.
The reflector is fixed on the crossbar using a bolt tightened due to which the reflector cannot
swivel in horizontal direction. Also there is no play for the bolt to move from its fixed position.
Fig 26: Array of Reflectors

21. ~ 14 ~
Our Solutions: - On the understanding of the problem we came up with two solutions.
1. Changing the design completely.
We came up with a new design to introduce the swivel in both directions. This could be
achieved by using a threaded bolt to couple the reflector. The bolt rotation in turn
rotates the reflector in horizontal (north - south) direction. The nut of the bolt is firmly
connected to the base of the reflector which is welded on the crossbar. The crossbar
provides the vertical movement (east – west). We can control the horizontal movement
by connecting a strip to the coupling of the bolt and reflector. This strip can be pushed
or pulled according the need of the focus. Further the vertical movement can be
controlled either manually or by sun tracking devices as discussed.
Fig 27: New Design Fig 28: Ball socket joint
2. Use of ball and socket joint.
A ball socket joint is a mechanical connection used between parts that must be allowed
some relative angular motion in nearly all directions. As the name implies, the joint
consists essentially of a spherical knob at the end of a shaft, with the knob fitting
securely into a mating socket. Like other mechanical joints, a ball-and-socket joint must
have some provision for lubrication and is normally provided with a seal to prevent loss
of the lubricant.
Advantages: - Cheap generation of electricity, environment friendly, no pollution.
Disadvantages: - Large area is required for installation, everyday cleaning of mirrors is required,
Sun tracking is manual, solar concentrator can work at the most 6 hours a day, it will not work
in rainy and cloudy season, solar energy is not for night, It is only during day.

22. ~ 15 ~
Solar Oven
Purpose: - To uniformly heat the substance, using a solar concentrator. It is most commonly
used for heating, baking and drying. Kilns and furnaces are special purpose ovens.
Design: - The solar concentrator of 39 glass mirror reflectors of 90 cm x 20 cm fitted on 3 rows
(13 on each row) on an inclined frame. Solar oven has an effective space 625 mm x 625 mm x
700 mm, complete with a door on the back and toughened glass on the front and packed with
cerawool insulations on all sides. Revolving drum of 500 mm diameter x 500 mm length made
up of wire. Netting is provided inside the oven for uniform distribution of heat. Common base
frame manually revolving on the vertical axis supporting solar concentrator and solar oven on 6
castor wheels.
Fig 29: Solar Oven
Advantages: - Effective heating surface, uniform heating surface, no fuel cost, one time
investment, low payback period.
Disadvantages: - Large space required, cleaning of mirrors regularly in important, manual
control.

23. ~ 16 ~
Scheffler Reflector
Purpose: - Scheffler Reflector is the ingenious device for concentrating sunshine and creating
heat up to much higher concentrations without any manual operation. It was invented by Mr.
Wolfgang Scheffler in Germany.
Design: - There are various sizes of reflectors such as 7.5 m2
, 8.5 m2
, 9.5 m2
, 11 m2
, etc. We
have described only one size of 11 m2
. Reflector dish is of elliptical shape 4.6 m × 3.26 m, made
of pipe structure on which glass mirrors are fitted in parabolic curves. Aluminum channels
support the glass mirrors. Entire reflector dish is mounted on the tracking device which is fitted
on the fixed stand and foundation frame. Reflector has sun tracking device by which it always
faces the sun. The specific feature of this reflector is that concentration point of the sunshine is
at the same place throughout the day even though reflector dish is moving along with the sun
from morning to evening. So it is possible to use the concentrated heat at the concentration
point which is somewhat away from the reflector dish.
Principle: - The working principle of the Scheffler
Reflector is based upon the focal point of the
parabola. Once focused, the entire incident
sunrays are reflected at the focal point Scheffler
reflector concentrates sunshine from a large
surface area of 11 m2
to a small spot of about 30
cm diameter i.e. concentration ratio is about 125
times.
Fig 30: Scheffler Working Principle
Operation: - Once focused early in the morning, the Scheffler Reflector operates with the help
of the sun mechanical tracking device, which rotates the reflector to face the sun throughout
the day without any manual interference. This is achieved by clockwork in which, a gear and a
chain are attached to a weight. As the weight goes down due to gravity, the chain pulls the
reflector and rotates it in the direction of the sun. Many kinds of sun trackers are available for
this purpose
Effectiveness: - The output of the reflector with a surface of 10 m2
varies depending on the
season of the year between 2.2 kW during to 3.3k W during winter, assuming a solar radiation
of 700 W/m2
. At our latitudes, the power (energy per unit) of the Scheffler mirrors is higher in
winters than in summers as the area of the mirror is used more effectively when the sun is
lower in the sky. The total energy received during a day is however still greater during summer
as there are more hours of sunshine.

24. ~ 17 ~
lower in the sky. The total energy received during a day is however still greater during summer
as there are more hours of sunshine.
Specifications: - For a Scheffler Reflector of size 8 m2
.
Parameter Quantity
Maximum Temperature reached in focus 1020o
C
Optical performance up with clear glass mirrors 84%
Optical yield maximum glass mirrors with normal 75%
Average power with radiation 700 W/m2 and normal glass mirrors 2.2 kW (1.7 to 2.5)
Maximum number of pots installed 3
Number of reflectors installed on largest solar cooker built in India 106 (18000 guests/day)
Material Cost to build reflector in India Approx. 550 Euros
Table 6: Specifications of Scheffler Reflector
Sun – Tracking Techniques: -
Fig 31: Sun Tracking Devices
Applications: - Community solar cooking, electricity generation by sterling dish system, steam
generation. In numerous food, pharmaceutical and chemical industries involving heating
process, Scheffler Reflectors have bright future.
Fig 32: Application of Scheffler Reflector
Advantages: - High Efficiency, Multi-purpose, Concentration point can be away from the dish,
economical, no fuel costs, can go up to very high temperatures, Low payback period.
Disadvantages: - Not portable, requires large space, glass reflectors are delicate, Seasonal
variable outputs, regular cleaning of reflectors.

25. ~ 18 ~
Biogas Plant
Purpose: - To extract gaseous fuel from biomass.
Biogas: - Biogas is produced by the anaerobic digestion or fermentation of biodegradable
materials such as manure, sewage, municipal waste, green waste, plant material, and
crops. Biogas comprises primarily methane (CH4) and carbon dioxide (CO2) and may have small
amounts of hydrogen sulfide (H2S), moisture and siloxanes. The gases methane, hydrogen, and
carbon monoxide (CO) can be combusted or oxidized with oxygen. This energy release allows
biogas to be used as a fuel.
Design: - The biogas plant comprises of a digester tank of 1200 l and gas holding tank of 800 l. It
is a cylindrical digester tank with an inverted cylindrical gas holding tank of smaller size inside it.
It comprises of a funnel shaped waste inlet, gas outlet, waste overflow outlet, waste drain
outlet and weights for pressurizing the gas. The mentioned design is the cheapest option for a
biogas plant. Every 2 kg organic waste can be fed duly ground in the mixer and added with 10 l
of water. It is suitable for a family of 5 persons.
Fig 33: Biogas plant design Fig 34: Biogas plant
Process: - The process of bio-gas production is anaerobic in nature and takes place in two stages. The
two stages have been termed as acid formation stage and methane formation stage. In the acid
formation stage, the bio-degradable complex organic compounds of solids and cellulose presents in the
waste materials are acted upon by a group of acid forming bacteria present in the dung and reduce
them into organic acids, CO2, H2, NH4 and H2S. Since the organic acids are the main products in this
stage, it is known as acid forming stage and this serves as the substrates for the production of methane
by methanogenic bacteria.
In the second stage, groups of methanogenic bacteria act upon the organic acids to produce
methane gas and also reduce CO2 in the presence of H2 to form methane (CH4). At the end of

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the process the amount of oxygen demanding materials in the waste product is reduced to
within the safe level for handling by human beings. There are four types of methano-genic
bacteria; Methano-bacterium, Methano-spirillium, Methano-coccus and Methano-circina.
These bacteria are oxygen sensitive and photo-sensitive and do not perform effectively in the
presence of oxygen and light.
Applications of biogas: - Fuel for cooking, fuel for boilers for localized power generation, with
minor modifications for conventional internal combustion engines.
Application of biogas plants: - Vegetable markets, Community toilets, Institutions, slaughter
houses, domestic purposes, rural villages, etc.
Advantages: - Cheap, ecofriendly, renewable source of energy, the output waste is an excellent
manure, any waste can be used, easy to operate, cleaner surroundings.
Disadvantages: - Occupies large space, when waste in low the pressure decreases, processing
the waste prior to introduction in the digester tank is compulsory.

27. ~ 20 ~
Steam Engine Operated Water Pump
Purpose: - To operate a pump simultaneously while operating a steam engine up to a distance
of 20 feet.
Design: - The main piston rod is extended further down to operate another piston in the pump.
The pump system comprises of piston head, inlet and outlet pipes; each split into two and non-
return valves in the pipeline.
Fig 35: Design of Steam Engine Operated Water Pump
Working: - When the steam engine starts functioning, the extension of the main piston rod
which is extended into the pump starts operating. When the piston moves up, suction is
created and the water flows into the pump; and when the piston moves down the pressure of
the piston head, the water is forced out from the outlet. Similarly, when the piston moves
down, suction is created and the water flows into the pump; and when the piston moves up the
pressure of the piston head, the water is forced out from the outlet. Thus a continuous
pumping is achieved. The non-return valves function to avoid any backflow of water. The pump
is effective for the distance up to 20 feet.
Applications: - Irrigation systems, pumping water from a well, etc.
Advantages: - Multifunction of the steam engine, high delivery rate, and easy maintenance as
construction is done by PVC pipes, and portable up to some extent.
Disadvantages: - Pump can be operated only where the steam engine is operated, large size.

28. ~ 21 ~
Pedal Operated Grain Mill
Purpose: - Milling of grains during the absence of electric power. The mill is intended for use
over brief periods to meet the day-to-day needs of householders. It is not intended to be used
intensively for long periods. The mill works at high speed and takes advantage of the smaller
effort required when the operator is using his legs rather than his arms to drive it.
Design: - The following drawing explains the design for the grain mill.
Fig 36: Components of Pedal Operated Grain Mill Fig 37: Assembled Pedal Operated Grain Mill
Working: - The mill itself uses a high-speed grinding action which is
broadly similar to that used by conventional powered hammer mills.
The operator turns the pedals at a normal brisk cycling speed. The
cycle wheel in turn drives a roller shaft on its outer edge at a speed of
about 5000 revs per minute. A fixed rotor arm is fitted to this shaft and
the grain is broken up after it is struck by the tip of the rotor. A
screening mesh controls the fineness of the grinding process. For a
given effort the output of the mill depends on the fineness of the
product required. The mill works best on hard, brittle grains such as
maize, millet and sorghum and on legumes such as soya beans. Fig 38: Working Model
Advantages: - No power required; works manually, cheap, portable, easy to install and operate.
Disadvantages: - Two operators required (one to operate the pedal other to feed the grain),
low output as compared to an electric grain mill.

29. ~ 22 ~
Wind Mill (VIRYA 1.04)
Purpose: - To harness the wind energy and convert it to electrical energy.
Design: - The VIRYA – 1.04 has a 3 bladed rotor with aluminum blades which are directly bolted
to the front flange of a Hub Dynamo. The hub dynamo is normally used in the form wheel of a
bicycle where it generates a nominal ac voltage of 6 V and a nominal electrical power of 2.4 W.
However, for wind mill use the 1-phase alternating current is rectified and the rotational speed
and so the voltage, are increased such that a 12 V lead acid battery can be charged. The
maximum power is about 6 W at a maximum charging voltage of 14 V. The maximum current
will be about 0.43 A; and it is expected that no voltage controller will be needed if a 12 V
battery of about 30 Ah is used.
The windmill will be equipped with the hind side vane safety system. However, the head will be
designed such that it can be made without welding. The head pipe and the tower pipe will both
be made out of a 1 m long ½ inch stainless steel gas pipe. The tower pipe can be connected to
the wooden pole by two clamping blocks. The vane blade will be made of 1.5 mm aluminum
sheet. It is expected wind speed is 8 m/s for the vane blade.
Specifications: -
Parameter Value
Diameter D = 1.04 m
Number of blades B = 3
Design tip speed ratio λd = 3.5
Gear ratio i = 1
Rotor eccentricity e = 0.09 m
Tower height for tower pipe only H = 1 m
Mass including 1m tower pipe m = 4.85 kg
Starting wind speed Vstart = 2.6 m/s
Survival wind speed Vsurv = 35 m/s
Cut-in Wind Speed (if started) Vcut in = 2 m/s
Rated Wind Speed Vrated = 8 m/s
Nominal Voltage 12 V DC
Power at rated Wind Speed P = 6 W
Table 7: Specifications of VIRYA 1.04
Various parts of the wind mill: -
1. Rotor
2. Bicycle Hub Dynamo
3. Vane arm assembly (Blade Assembly)
4. Tower pipe
5. Safety System
6. Control system (Battery Charge Controller)

30. ~ 23 ~
Fig 39: Windmill – VIRYA 1.04
Importance and Calculation of Tip Speed Ratio: - The Tip Speed Ratio (TSR) is an extremely
important factor in wind turbine design. TSR refers to the ratio between the wind speed and
the speed of the tips of the wind turbine blades. If the rotor of the wind turbine spins too
slowly, most of the wind will pass straight through the gap between the blades, therefore giving
it no power. But if the rotor spins too fast, the blades will blur and act like a solid wall to the
wind. Also, rotor blades create turbulence as they spin through the air. If the next blade arrives
too quickly, it will hit that turbulent air. So, sometimes it is actually better to slow down your
blades. Wind turbines must be designed with optimal tip speed ratios to get the maximum
amount of power from the wind.
Finding The Tip Speed: -
1. Measure the rotor radius (length of one blade)
2. Speed = distance divided by time. The distance travelled is the circumference (2Πr).
3. Speed:
V =2πr/T
The blades travel one circumference (2πr) in a rotation time of T (seconds).
Now you see why we need to know how long it takes to make one full revolution.
Knowing the perfect tip speed ratio: -
The optimum Tip Speed Ratio for maximum power output, this formula has been empirically
proven:
λ (max power) =4π/n (n = number of blades)

31. ~ 24 ~
Applications: - Rural homes having low power utility.
Advantages: - The gyroscopic movement is not fluctuating, light-weight, portable, cheap, easy
to install, Automatic control to avoid overcharging.

32. ~ 25 ~
Other Areas
During the course of our internship, we also got an opportunity to visit various other industries.
Thus, the scope of our internship was not limited to any particular aspect. The various
industries are listed as follows: -
1. Tinytech Plants Pvt. Ltd.
It is a company that is promoting small scale industries to empower the lower strata of
the society. During our visit there, we were able to witness the manufacture of various
products such as: -
i. Mango Pulp Machine
ii. Banana wafer plant
iii. Coconut grinding Machine
iv. Oil refinery
v. Oil mill
vi. Potato wafer plant
Fig 40: Mango Pulp Machine Fig 41: Banana Chips Machine Fig 42: Coconut Grinding Machine
Fig 43: Oil refinery Fig 44: Oil Mill Fig 45: Potato Wafer Plant

33. ~ 26 ~
2. Amul Enterprises
It is a company manufacturing diverse range of products. During our visit there, we were
able to witness the manufacture of various products such as: -
vii. Popcorn Machine
viii. Surgical Equipment
ix. Railing Components
x. Pipe Clamps
Fig 46: Popcorn Machine Fig 47: Surgical Equipments
Fig 48: Railing Components Fig 49: Pipe Clamps

34. ~ 27 ~
3. Aditya Engineers
It is a company manufacturing high quality electrical products. Quality and labor welfare
is a priority for them. During our visit there, we were able to witness the manufacture of
various products such as: -
i. Induction Motors
ii. Domestic Grain Mill (Automatic)
Fig 50: Induction Motor Fig 51: Domestic Grain Mill
4. Akshar Engineering
It is a company manufacturing commercial products for small businesses like: -
i. Sugarcane Crushing Machine
ii. Manually Operated Air Blower
Fig 52: Sugarcane Crusher Fig 53: Air Blower

35. ~ 28 ~
5. Ramdev Engineers
It is a company providing powder coating services. It comprises of powder coating,
baking and cooling.
Fig 54: Powder Coating Procedure
6. Ganga Industries
It is a company manufacturing aluminum vessels, storage containers, etc.
Fig 55: Aluminum Products
7. Shree Ganesh Industries
It is a company manufacturing flexible plastic pipes for carrying water for agricultural
fields.
Fig 56: Pipe Drawing Fig 57: Rolling for packaging Fig 58: Raw Material (Plastic)

36. ~ 29 ~
8. Aashapura Industries
It is a company manufacturing cast iron components for various purposes in various
industries.
Fig 59: Molten iron from the furnace Fig 60: Pouring the molten iron into the dye.
9. Jayson Engineering Company
It is a company manufacturing automobile piston rods for various automotive industries.
Fig 61: Piston Rod Assembly

37. ~ 30 ~
References
www.tinytechindia.com
www.wikipedia.com
Kragten Design
Appropriate Technology Library