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Wood gasifier
This document discusses a project to design and manufacture a wood gasifier for use in Vietnam. It analyzes available biomass materials like rice straw and proposes gasifiers as a solution to provide clean cooking energy while producing biochar as a soil enhancer. The group analyzes the gasifier and biochar markets in Vietnam, estimates costs of production, and outlines procurement, sales and distribution strategies. It also discusses stakeholder interests, job creation, and protecting resources. Experimental results from other projects show increased crop yields from using biochar and the efficiency of gasifiers over open fires. The group evaluates technical options and identifies the TLUD stove as the best solution to meet requirements.
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Wood gasifier
- 1. Project: Create a Wood GasifierforVietnam Lecturer: Dr. Peter Stammnitz Group 2: ĐặngTiểu My- Factory planner Trần Kim Ngân- Economist Trương Thị Xuân Đào- Project coordinator Nguyễn Hồng Khánh- Factory planner Nguyễn Kim Ninh- Manufacturing expert Nguyễn QuangThanh-Designer April 2014 1
- 2. Introduction • Bio charcan use as fertilizer when mixed with compost. • Affordable design will encourage people use clean cook stoves . • Reduce pollution because burning crop residue by Gasifiers only produces CO2 Solution:The role of Gasifiers • Enormous demand of fertilizer because of soil degradation problems. • Prefer cheaper but toxic coal cook stoves due to costs of LPG are rising. • Burning crop residue is polluting the environment. Consequences • 79.5%(*) total land use is agricultural land. • 68%(*) population lived in rural can not afford the LPG cookstove • Heavily dependent on agriculture (69.5%(*) of labour force). Facts (*)Viet Nam statistics book 2012 2
- 3. Application of biochar Bio char Producea soil enhancer Produce clean, renewable energy Reduce agricultural waste Fight global warming (*) http://www.biochar-international.org 3
- 4. Part one 1 •Analysis material 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs,protection of resources 6 • Exist practical experiment results 4
- 5. Rice husk andstraw • Location: 20% in Red river delta and 50% in Mekong river delta. • Current usage: Cooking (15%), brick kiln (40-45%),power plant, briquette (10%), left over (20-25%) Sugar cane • Location: Mekong River Delta, North Middle and Coastal Plain, and East South • Current usage: 50-60% combustion in Furnace, fertilization Corn cobb Location: 50% Northeast and 10% in south east • Current usage: animal feed, cooking, fertilizer Coconut husk • Location: 84% in Mekong Delta (Ben Tre 30%) • Current usage: 100% shell: activated carbon or domestic fuel or industrial thermal. 96% husks: processed into coir Coffee husk • Location: the Central Highlands and the North • Current usage: Combusted, fertilizer, dumped *Biomass Business OpportunitiesViet Nam by SNV Netherlands Development OrganisationVietnam Analysis of material inVietnam*(2/2) 5
- 6. Analysis of materialinVietnam*(2/2) Material Area ( Ha) Yield / Ha % residue Theoretical Availability Rice husk 7,500,000 ha 5.32 t/ha 20% 8 million ton Rice straw 85% (on average) 23 million ton Sugar cane 266,000 ha 63.9 t/ha Top: 30%, leaves:10%, Bagasse: 9% Top: 4,110,150t; Leaves: 1,370,050t; Bagasse: 1,233,045t. Corn cobb 1,125,000 ha 4.0 t/ha 20-50% 1,066,500 tons Coconut husk 130,000 ha 13 t/ha 30% weight is husk 975 tons Coffee 500,000 1.8 t/ha 15% of the dried cherry weight 135,000 tons *Biomass Business OpportunitiesViet Nam by SNV Netherlands Development OrganisationVietnam Conclusion: Rice straw can be identified as the largest potential. 6
- 7. Sustainable rice strawmaterial flow 7
- 8. Part one 1 • Analysismaterial 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs,protection of resources 6 • Exist practical experiment results 8
- 9. Technical principle(*) The updraftgasifier • Pros: Small pressure drop, good thermal efficiency, little tendency towards slag formation • Cons: Great sensitivity to tar and moisture and moisture content of fuel, poor reaction capability with heavy gas load. The downdraft gasifier • Pros: low sensitivity to charcoal dust and tar content of fuel, flexible adaptation of gas production to load. • Cons: Design tends to be tall, not feasible for very small particle size of fuel The Crossdraft gasifier • Pros: Short design height, very fast response time to load, flexible gas production • Cons:Very high sensitivity to slag formation, high pressure drop. (*) “Alternative Energy in Agriculture”,Vol. II, Ed. D.Yogi Goswami 9
- 10. Existing technical solutions(*) Rocketstove Pro: need less fuel, produce clean air Cons: Must be used with a thermal mass for efficiency Anila stove Pro: very sturdy, easy to learn to use, works fine Cons: not work well on clearly sub zero temperatures Biochar rocket stove Pro: can be used in door, easier to control the temperature Cons: increased emissions, possible incomplete pyrolysis TLUD stove Pro: absence of smoke Cons: not ideally suited for use indoors (*) http://www.soil-carbon-regeneration.co.uk/biochar/biochar-stoves-2/ 10
- 11. Part one 1 • Analysismaterial 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs,protection of resources 6 • Exist practical experiment results 11
- 12. Gasifier market Targetgroups: potential customers are farmers in the Northern Highlands, Central Highlands, and Mekong Delta(*), especially ethnic minority groups who only can afford cook stoves with little to no subsidies. In 2012, population in rural area is 60416,5 thousand person, with six members per household on average.Therefore, the number of rural households inVietnam was about 10 million. In conclusion, the Gasifier market is estimated up to 10 million. (*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 12
- 13. Biochar Market Agricultural land 26280,5 thousand ha Application of0.5ton biochar/ha /year(*) Quantity of biochar on demand: 13.14 thousand ton/year (*) http://internationalinventjournals.org/journals/IJASS 13
- 14. Biochar cost analysis Biocharcost: 2.250VND/kg Risk ratio: 0.5 Costs toward rice straw material: 300 VND/kg Yield of biochar was approximately 20-23% (*) (*) http://www.biochar-international.org/profile/Stoves_in_Vietnam 14
- 15. Gasifier cost analysis Gasifiercost: 600,000VND Labour cost: 150000 VND Material cost: 380.000VND Manufacturing overhead: 70000VND 15
- 16. Part one 1 • Analysismaterial 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs,protection of resources 6 • Exist practical experiment results 16
- 17. Procurement Material Price Technicaldata Mild steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm Stainless steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm Roll steel 14500vnd/kg Ø8xroll Rectangular steel 14500vnd/kg 4x40x100mm Rectangular steel 14500vnd/kg 2.5 x25x25mm Rectangular steel 14500vnd/kg 2x30x30mm 17
- 18. Sales & DistributionStrategy(*) • The Northern Highlands, Central Highlands, and Mekong Delta • Choose regions that have potential for longitudinal effects, Determine which target regions • Create incentive commission structure that motivates the promoter to encourage wide-scale adoption Determine specific promoters have the best reach within target regions • Understand which channels have the best reach within target communities • Focus on word-of-mouth marketing, which is key inVietnam culture Create marketing campaign to establish branding and generate awareness (*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 18
- 19. Part one 1 • Analysismaterial 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs, protection of resources 6 • Exist practical experiment results 19
- 20. Stakeholders analysis Stakeholder Problem/ Constrain MainInterest Potential Project group Short of time Finance secure Practical experience Profitable business but sustainable develop Knowledge to approach new technology Rural community Lack of skill Poverty Soil degradation Increase income, Improve living qualification but low cost Agricultural waste Government Pollution, Soil degradation Pressure on energy demand Renewable energy, poverty reduction Power of policymaker Foreign NGOs Direct contact to local people, unfamiliar to local habit Sustainable rural development Funding, project management experience 20
- 21. Our Gasifier remarkablevalue Raw material Production Sales and distribution Maintenance Product development Gasifier Stable supply, low cost Low cost, portable, easy to use Provide training in self-repair sustainable business models Affordability ,last mile distribution, self-built construction 21
- 22. Job Creation Value Transfertechnology to customers, farmers… Built plant local labor absorption (http://pamoja.se/) 22
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- 25. Part one 1 • Analysismaterial 2 • Technical solutions 3 • Analysis markets, prices, costs 4 • Procurement analysis, sales strategy 5 • Stakeholder, value, jobs,protection of resources 6 • Exist practical experiment results 25
- 26. Result of BiocharTreatmentand its Effects on Rice andVegetableYields in Mountainous Areas of Northern Vietnam (*) “Application of 0.5–2.5tons biochar/ha combined with NPK, average rice yield was increased by 17.6%. Economic benefit from rice cultivation is estimated by 29.11- 37.05 million VND/ha/crop with net income of 2.64- 7.26 million VND/ha/crop.” (*) by Vinh NC. , Hien NV.,Anh MTL., Johan Lehmann, Stephen Joseph 26
- 27. Results of comparisontest of CAREVietnam Gasifier stove Open fire The amount of used wood (gram) 955 - 1235 2000 Total weight of food (gram) 1850 1850 Total weight food/total weight wood 1.5 – 1.94 0.93 Total time for cooking rice to simmer (minutes) 29 - 34 32 Conclusion: in the same period of time, with less used wood (955 to 1235 gram), gasifier stove can cook the same weight of food as the traditional open fire with 2000 gram. 27
- 28. Part two 1 • Creationof Design 2 • Design for manufacturing 3 • Factory planning 4 • Further expand project recommendation 28
- 29. Productivity (to generate charcoal) Life timeIndoor usable Low cost Rapid heat transfer Safety Portable Easy to ignite Cleanliness Machinable Flexible with various biomass Easy to remove charcoal Product requirement and technical specific 29
- 30. Evaluation for bestsolution Rocket stove TLUD stove Anila stove 30
- 31. No Requirement Weight(%) TULD stove Anila stove Biochar rocket stove 1 Low cost 20 2 3 1 2 Portable 15 3 3 1 3 Easy to remove charcoal 10 2 3 1 4 Cleanliness 10 2 3 1 5 Productivity 10 3 2 1 6 Flexibility with raw material 5 1 1 3 7 Usable indoor 5 3 3 1 8 Easy to ignite 5 2 3 1 9 Rapid heat transfer 5 3 3 1 10 Life time 5 1 2 3 11 Safety 5 2 3 2 12 Machinable 5 2 3 1 Total 100% 225 275 125 Base on above analysis, we select Anila stove type to improve such feature for high adaptation with the requirement. Evaluation for best solution 31
- 32. Principle Sketch Crosssection Principle sketch 32 Fuel Biomas Biomas
- 33. Ambient Air HotAir Fan Heat Exchanger (Optional) Heating by burning charcoal indoor cause many deaths in winter in NorthViet Nam Our heat exchanger provide rural community a environmental and economic heating solution 33
- 34. Laminar Flow Temperature higherin centre. Insulating film on Tube surface Poor heat transfer Turbulent Flow Good mixing Breaks down insulating film Better heat transfer Spiral Tubes34 Comparing between Spiral Tubes and Straight Tubes 34
- 35. 01.Top lid 02. Biomasschamber 03. Outer housing 35 Height: 600mm Width: 420mm Weight: 25kg Biomass volume: 37 dm3
- 36. Part two 1 • Creationof Design 2 • Design for manufacturing 3 • Factory planning 4 • Further expand project recommendation 36
- 37. Bill of material Biomass chambercoil Combustion chamber coil Outer housing Bottom plate Biomass chamber legs Cover plate Top lidBiomass chamber lid Combustion chamber Biomass chamber 37
- 38. Top lid PotstandTop Lid and Small Lid Part Name Technical specific Material Process Top lid Outer diameter: 430 Inner diameter: 150 Thickness: 2 Mild steel sheet Cutting Die Forging Pot stand Length: 100 Width: 30 Thickness: 2 Rectangular steel Cutting Biomass chamber lid Outer diameter: 370 Inner diameter: 100 Thickness: 2 Mild steel sheet Cutting Die Forging Biomass chamber lid handle Length: 25 Width: 25 Thickness: 2 Rectangular steel Cutting PROCESS FOR PRODUCE SINGLE COMPONENT 38
- 39. Biomass chamber (1/2) PartName Technical specific Material Process Biomass chamber tube Diameter: 360 Height: 380 Thickness: 2 Stainless steel sheet Sheet cutting Forming Welding Biomass chamber coil Diameter: 380 Pitch: 50 Revolution: 6 Roll steel Forming Bottom plate Outer diameter: 360 Inner diameter: 80 Thickness: 2 Stainless steel sheet Die forging Biomass chamber leg Height: 135 Length: 50 Width: 30 Rectangular steel Cutting Biomass chamber tube Biomass chamber coil Bottom plate Biomass chamber leg 39
- 40. Combustion chamber Part NameTechnical specific Material Process Combustion chamber Height: 420 Diameter: 100 Thickness: 2 10 Hole: D=30 Stainless steel tube Cutting Drilling Combustion chamber coil Diameter: 96 Pitch: 50 Revolution: 6 Roll steel Forming Combustion chamber Combustion chamber coil 40
- 41. Cover: Part Name Technicalspecific Material Process Outer housing Diameter: 420 Height: 550 Thickness: 2 Mild steel sheet Cutting Drilling Forming Bottom plate Diameter: 420 Thickness: 3 Stainless steel sheet Cutting Handle Length: 160 Width: 66 Thickness: 3 Bar steel Cold forging Outer Housing Bottom plate Handle 41
- 42. Sub Name Part Name ProcessEquipment 1 Top lid + Pot stand Arc welding MIG Welder 2 Biomass chamber lid + Biomass chamber lid handle Arc welding MIG Welder 3 Biomass chamber tube + Biomass chamber coil Arc welding MIG Welder JOINING PROCESS 42
- 43. Sub Name PartName Process Equipment 4 Combustion chamber + Combustion chamber coil Arc welding MIG Welder 5 Bottom plate + Biomass chamber leg Arc welding MIG Welder 6 Sub 4 + Sub 5 Arc welding MIG Welder JOINING PROCESS 43
- 44. Sub Name Part Name ProcessEquipment 7 Sub 3 + Sub 6 Arc welding MIG Welder 8 Sub 7 + Cover Plate Arc welding MIG Welder 9 Cover housing + Handle Arc welding MIG Welder 10 Sub 8 + Sub 9 (Finish) Arc welding MIG Welder JOINING PROCESS 44
- 45. Equipment and Machinery http://kzwmachine.en.hisuppli er.com/product-161793- steel-tube-cutter.html http://www.alibaba.com/product- detail/Milling-cum-Drilling- Machine_104953739.html http://www.asia.ru/en/ProductInfo/13416 82.html http://www.rexhydraulics.com/gene ral/Gallery.aspx?gid=14 http://www.alibaba.com/product- detail/air-hammer_338304017.html Forgingmachine http://www.directindustry.com/prod/st eeltailor/portable-cnc-plasma-cutting- machines-35080-1172087.html Cutting machine Hydraulic plate rolling machine Drilling machine MAG/MIG welding machine Steel tube cutter 45
- 46. Part two 1 • Creationof Design 2 • Design for manufacturing 3 • Factory planning 4 • Further expand project recommendation 46
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- 48. Production programs planning 48 Production Program CuttingJoining Inspection PackingFormingForming Market forecast Supplier 1 Supplier 2 Customer A Customer B Aaaa aa • Implement the flow assembly: ‘one piece flow’ • Highest flexibility on customer demand • Reduction of space, inventory and throughput time Shipping 3 people 2 people 3 people 2 people Cuttin g Cuttin g Cuttin g C/T306s C/T312s C/T295s C/T280s
- 49. Capacity Planning Population inThaiNguyen: 1.1 million Population in rural area: 0.8 million Demand: 130 thousand products First phase: 5 years Capacity: 26,000 products/year 90 products/day(300 working days/year) Thai Nguyen is selected as first market due to: - Many experiments gasifier conducted inThai Nguyen. - Local community’s awareness toward gasifier - Concentrates ethnic minorities. Second phase: copy the first model fromThai Nguyen toThanh Hoa after 2 years of first phase 49
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- 53. Organisation chart 53 Director 1 person Accountant 1person HR 1 person R&D 2 persons Production 12persons Cutting 2 persons Drilling 1 person Forming 2persons Joining 3 persons Inspect 2persons
- 54. Part two 1 • Creationof Design 2 • Design for manufacturing 3 • Factory planning 4 • Further expand project recommendation 54
- 55. Expanding objective customers 1.BBQ restaurants Existing restaurants and their current technologies : BBQ garden, Sumo BBQ, Hana BBQ, BBQ Smoke, BBQ straw, … Using char coal Using gas stove 55
- 56. Advantages of usinggasifier stove - Reduce cooking fuel expenditure : Material: compressed rice husk (1620VND/kg),rice husk firewood (1290VND/kg), … Compared with: coal : 5000VND/kg gas : 400 000VND/12kg - Friendly environment -> Sustainable development -> Establish good reputation. - No harmful exhausted gas Expanding objective customers 1. BBQ restaurants 56
- 57. * Nowadays, peopleshow their deep concern about the environmental protection, especially educated people, who have potential to possess our green villas project. * Main reasons: - Harmful vegetable by overuse pesticide as well as chemical fertilizer. need clean vegetable. - Energy saving - Establish good reputation Expanding objective customers 2. Project to build green villas 57
- 58. Expanding objective customers Projectto build green villas Using gasifier stove for cooking (Material: compressed rice husk, … bought from the market) Using biochar for planting vegetable on garden around Utilize heat from the output gas for heater or heating pool 58
- 59. Gasifier market:up to 10 million/year. Biochar market: over 13 thousand tons/year. Technical solution:“Improved “Anila Gasifier. Target cost: 600.000VND/gasifier (approximately 29 USD). Factory capacity: 90units/day Project Summary 59
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