Rural Technology Brochures

8/2/2019 Rural Technology Brochures

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Institute of Minerals and Materials Technology(Council of Scientific & Industrial Research)

Bhubaneswar 751013

MULTI PURPOSE BIOMASS DRIER

The drier is used for drying and heating of various agricultural and food products and industriamaterials in a clean environment within a temperature range of 50-2000C generated through burning ofbiomass. It is particularly suitable for drying of noodles, vermicelli, potato chips, cut vegetables, tea leaffruits, household kitchen preparations (like papad, badi), spices (like zinger, onion, garlic), cereal andpulses, parboiled rice, fish, meat, and industrial products (like textiles). It is also useful in baking of paint(heat paint) over auto-mobile and furniture etc. The product is patented in India (IN 715415).

Product Features

This is a cabinet type portable apparatus which consists of a fuel efficient combustor, a heatexchanger and a drying chamber with collapsible racks in an integrated manner. Firewood/biomassburns completely without emitting smoke inside the combustor. The heat flux is transmitted indirectly

from the hot flue gas to the drying materials through the heat exchanger. The flue gas never comes indirect contact with the drying materials inside the drying chamber, for which high quality dryingequivalent to electric operated drier is always achieved. The flue gas is released outside of the drierthrough a chimney. The internal design helps the drier to maintain uniform temperature for drying ofdifferent materials. Overall thermal efficiency of the drier is as high as 80%. Nearly 60-70% reductionin energy, cost and drying time is achieved in comparison with electric heated drier. Average woodconsumption for drying is @ 3.5 kg/hr.

Raw Material, equipments and gadgets required for fabrication

Mild steel angle and sheet, Plywood, Thermo cool and G.I.sheet

Welding and drilling machines, normal hand tools

Unit Cost: 1 Cubic meter size = Rs.20, 000/-2 Cubic meter size = Rs.30, 000/-4 Cubic meter size = Rs.40, 000/-

S.Khuntia,Chief Scientist & Inventor

CSIR-Institute of Minerals and Materials Technology, Bhubaneswar-751013, Odisha, IndiaPhone: (0674) 2379219 Fax :(0674) 2581637, Mob: 09437012679

Email: [email protected] , [email protected] , [email protected]


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Bhubaneswar - 751013

BIOMASS FIXED CHULHASWITH CHIMNEYSK-1, SK-2, SK-3 (FAMILY, MEDIUM, LARGE), SK-4 models

Energy efficient low cost fixed chullhas (cook stoves) are used for cooking with reduced fuelconsumption and without smoke inside the kitchen. Biomass, agro-waste and dung cake etc. are burntin the chulhas for cooking at high thermal efficiency (25%), which saves 40% fuels over the traditionalchulhas. Exhaust gas from the chullha is released outside of kitchen through a chimney. The chimneyprotrudes through the wall or roof of the kitchen for de-carbonization of the chimney.

Product Features

Fuels burn completely in the chullha due to continuous flow of air over the char. Unburnt fuels insidethe hearth of the chullha by the suction effect of the chimney. Hot flue gas or smoke does not leak intothe kitchen as a low pressure is always maintained inside the chullha. High rate of heat transfer fromthe flame to the cook pot is achieved during burning, as the flame and hot flue gas always glide over

bottom surface of the cook pot before released to the chimney. Simple design with cylindricacombustion chamber of the chullha ensures easy construction, high thermal efficiency, care free useand high acceptability among the users.

Raw material, equipment and gadgets required forfabrication

Pre-fabricated terracotta components, Clay, Ordinaryred brick and asbestos cement pipe

Potters wheel, Mould, Fixtures and Low cost furnace

Unit Cost: Rs. 100-200 as per capacity





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PORTABLE MULTI FUEL COOK STOVES

(HARSHA, HARSHA COMMUNITY, JYOSTNA)

Portable multi fuel stoves are used for cooking in smokeless condition with reduced fuel consumptionand pollution. A variety of solid fuels such as firewood, twig, leaf, dung cake, agricultural wastes,charcoal, briquettes, bagasse etc. can be burnt in the stoves with high thermal efficiency (30-50%)irrespective of physical/chemical characteristics of the fuels. The product is patented in India (IN166168).

Product Features

This is a metallic stove with corrugated grate and perforated combustion chamber and is provided withan ash scraper. Fixed carbon and volatile parts of the fuels burn separately inside the corrugated grateand perforated combustion chamber of the stove respectively. Complete combustion of fuels with less

excess air is achieved due to continuous flow of preheated air, in primary and secondary streams, intothe stove through natural draft. The ash scraper helps to remove ash intermittently during burning ohigh ash fuels. Ash also comes out automatically from the stove. The multi-fuel combustion designfacilitates to achieve clean and high temperature flame. Fuel saving over the traditional cook stoves is50%. Cooking capacity for different size of the stoves is from 5 to 500 persons.

Raw material, equipments and gadgets required for manufacture

Mild steel sheet

Welding machine, Ball press or Power press, sheet cutting machine

Unit Cost: Rs. 350-2500/- as per cooking capacity





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Bhubaneswar 751013

BIOMASS OPERATED BAKERY OVEN

It is a wood fired bakery oven suitable for tiny bakery units and households. The oven is low cost andportable in nature. Confectionaries like breads (loaves), cakes, biscuits and cookies can be bakedeffectively in uniform temperature by burning biomass in the oven. The oven does not require pre-heating and attains the required temperature for baking within 15 minutes after ignition of fuel. Itconsumes quite less fuel, for which 60% reduction in baking cost and time is achieved in comparisonwith the traditional bakery ovens. More than 32 pieces of loaf (400gm each) can be baked in an hourconsuming only 4 kg firewood by one person. The product has been patented in India (IN 715415).

Product Features

The product comprises of a combustor, an insulated oven and a chimney, which are connectedinternally. Biomass burns completely inside the combustor and hot flue gas flows from combustor to theoven through suction effect of the chimney. Uniform temperature inside the oven is easily obtained foreffective baking of various confectioneries due to downdraft principle operational in the oven. Smokeand related pollution is greatly reduced by complete combustion of fuels through primary andsecondary air streams in the combustor.

Raw material, equipments and gadgets for fabrication

Mild steel sheet and sections, GI sheet

Welding and drill machine, Hand tools for fabrication Cost of oven: Rs.6,500/-





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LOW COST TERAFIL WATER FILTER

TERAFIL is a low cost burnt red clay porous media (disc/candle), used for filtration and treatment of turbid rawwater into clean drinking water for domestic/community usage. Suspended particles, sediment, iron and manyheavy metals, micro organism, colour and bad odour etc. are separated from raw water effectively during filtrationwithout clogging the core of the TERAFIL. It can be fixed with any container for purification of water. Quality ofproduct water is within BIS limits, especially for turbidity, iron and micro organisms. Cost of purification is withinRs. 2/- per ton of water, considering total cost of plant. It operates without electricity, spent water and sludgemanagement. Average life of TERAFIL media is five years. Terafil water purification systems are available indifferent capacities ranging from 1 to 50,000 lit/day.

Product Features

TERAFIL is prepared out of a mixture of sand, red clay and wood saw dust. Terafil media comprises of thin clay

walls (clay membranes) each of which is separated by large size pores. The thin clay walls contain ultra-finecapillary openings (sub-micron in size) which bridge the pores. Water flows from one pore to anther throughcapillary openings during filtration in Terafil media, leaving behind sediments, suspended particles etc on topsurface of the filtration disc. This leads to availability of clean drinking water. Terafil is fitted at the bottom of anycontainer for filtration and treatment of water.

Raw Material, equipments and gadgets for production

Pottery clay, sand and wood saw dust for preparation of TERAFIL disc.

Chambers made of clay, metallic, plastic, ferro-cement, brick wall etc forcomplete water filter.

Atta-chakki (small wheat pulverizer), vibrating sieve, hand moulds,manual/electrical operated mixer, mixing tank, platform

Queen coal/wood fired pottery kiln or mold for plastic container

Unit cost of Terafil disc

Size 100 mm diameter: Rs.15/-, with food grade plastic holder Rs. 25/-Size 200 mm diameter: Rs.60/-, with food grade plastic holder Rs 120/-





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PULSE THRESHER-CUM-WINNOWER

This machine is used for efficient threshing and winnowing of matured crop of different pulses

irrespective of shape and size of plants or grains. It can be applied for green gram, black gram, arharhorse gram, lentil etc., with minimum power consumption and labour input. The crop residue issimultaneously crushed to a powdery material during threshing that can be used as animal feed. Abou50% harvesting cost is reduced and 10% yield is increased over the traditional threshing methods sincegrain loss in crop residue is reduced to almost nil and the rate of operation is 2 to 3 times faster with athreshing and winnowing capacity of 600 kg/hr of the dry crops. The machine operates by 2 or 3 hpelectric motor or oil engine. Semi-automatic and fully automatic pulse thresher variants are alsoavailable.

Product FeaturesThe machine is a vertical flow thresher and dry crop moves vertically inside the machine. Opening opods and crushing of crop residues are carried out by a shear mechanism of the fixed and movingbeaters of the machine. The grains are separated from the crop residue by the winnower. Threshingefficiency is more than 99%. The unique feature brings down the breakage of grain to almost nil. The

average cost of threshing and winnowing (including labour and fuel) is 31 paisa per kg of grain. Thegermination of the grains is as good as hand threshed grains.

Raw material, equipments and gadgets required

Mild steel sheet, angle, single phase 3hp motor or kerosene/diesel engine, bearing, EN shaftblower, sieve etc.

Lathe, welding machine, shearing and cutting machine, drilling machine

Unit cost: Rs 80, 000/-with 3.1 hp petrol start kerosene/diesel run water pump setRs 60,000/- with single phase 3 hp electric motor & starter





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LOW COST DRIER FOR LARGE CARDAMOM AND SPICES

Major component of the cardamom drier is the wood combustor, which generates clean and hot gas fordirect heating and drying of large cardamom (spice) raw capsules in cardamom growing areas of IndiaThe combustor burns firewood completely in a smoke free environment and reduces 75% woodconsumption and curing period thereby improving the quality of the dried cardamom. About 45%increase in the content of essential oil of the dried cardamom is observed over the traditional dryingmethods. The drier can also be used for drying of other spices like chilly, ginger, garlic etc.

Product Feature

The wood combustor, equipped with corrugated grate, perforated combustion chamber, hood etc., isportable and detachable. The combustor burns firewood completely with the help of primary and

secondary air streams for generation of clean hot gas. The combustor is placed at the bottom of abrick/mud walled chamber or inside the traditional Bhatti. The top portion is covered with a steel wirenet or bamboo mat for holding the raw cardamom capsules. The wood combustor supplies the hot gasbelow the wire net at a uniform temperature for drying the spices. Method of drying of cardamomcapsules is alike the traditional process to maintain quality and obtain high acceptability among thefarmers.

Raw material, equipments and gadgets required for fabrication

Mild steel angle and sheet, G.I. sheet, brick or mud wallWelding and drilling machines, hand tools

Unit Cost1 m3 size: Rs.12, 000/-, 2 m3 size: Rs.18, 000/-, 4 m3 size: Rs.26, 000/-





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QUEEN COAL / WOOD FIRED POTTERY KILN

The Queen kiln is a low cost coal or wood fired furnace made up of red brick and clay. It sinters(baking) all kinds of potteries/terracotta material such as handicrafts, domestic earthenware, roof tiles

and TERAFIL water filtration disc/containers etc. at a uniform high temperature (800-9000C) using low

grade coal or wood, as per availability in the vicinity. The improved kiln reduces about 2/3 rd fueconsumption, sintering period and labour requirement while bringing down the level of pollution over thetraditional pottery kilns. The quality of the potteries is superior and breakage of the potteries is almostnil during sintering. The structure is suitable for tiny and cottage industry.

Product Features

The kiln is a downdraft tunnel type permanent structure inbuilt with a short height chimney. Uniformtemperature is easily obtained in few hours during its operation, for which breakage of potteries is

negligible and quality of terracotta is superior. Loading and unloading of potteries are simple andcarried out through a door. Firing of potteries is not labour intensive unlike traditional pottery kiln. 100firing per year.

Raw materials and equipments required for fabrication

Mild Steel Angle, rods, red brick, clay and sand

Temperature measuring instruments.

Installation cost : Rs 30,000-60,000/- depending upon the volume in the range of 2.5-12m3





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POWER OPERATED PADDY THRESHER-CUM-WINNOWER

The power operated paddy thresher-cum-winnower is used for efficient threshing of paddy (completeremoval of grains from paddy plants) with reduced grain loss in the crop residue and less labour inputThe thresher operates by a 1hp electric motor or oil engine. The machine is attached with a winnower,which is used for effective cleaning of various grains such as paddy, wheat, cereals, pulses etc. duringharvesting. Threshing capacity of the machine is 300 kg grains/hr with winnowing capacity of 500 kggrains/hr.

Product Feature

It is a hold-on type thresher and contains a rotating drum. U-shaped spikes are fixed on the outersurface of the drum for maximum removal (99%) of grains when the bundles of ripe paddy plants are

shown to the rotating drum. It reduces 60% threshing cost and increases 10% yield in comparison tothe traditional threshing methods. The winnower consists of a vibrating tray and a fan. The tray fluidisesthe uncleaned grains and subsequently the lighter material is carried to a distance place by the airstream generated by the fan fitted below the fluidiser. Both the drum and the fan are operated by a 1hpelectric motor or oil engine. Higher degree of cleaning of grains is achieved due to use of the fluidiseand fan.


Mild steel angle, steel sheet, bearing, V-belts, 1-hp electric motor or oil engine Welding machine, sheet cutting machine, jig and fixture

Unit Cost: In the range of Rs 12,000-20,000/-





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BIOGAS FROM VEGETABLE AND KITCHEN WASTES

Decomposed and spoiled vegetables and kitchen wastes are minced to pulp in a mincing machine. Thepulp undergoes ultra-sound treatment for ten minutes for fast generation of bio-gas before charging toreactor. The minced vegetables can be straightway charged to bio-gas reactor for generation of biogasas well. Gas thus obtained from the reactor contains 70-80% methane which can be used for cleanburning, cooking and heating without smoke and pollution. Wastes from vegetable market can beconverted into clean cooking gas by using the machine.

Product Feature

Spoiled vegetables are minced to pulp bellow 10 mm size in an efficient mincing machine designed byIMMT. The pulp is then charged to the specific bio-gas reactor. Methane enriched biogas are generated

in the reactor within 30days. 5kg/day decomposed vegetable is sufficient to provide a clean blue flamethat can be connected to any domestic gas burner for one hour of cooking and heating that iscomparable with LPG. The spent sludge is mostly a gray liquid, which can be re-charged with feedmaterials to reduce water consumption.

Raw material, equipment and gadgets required for fabrication

Mild steel angle, steel sheet, bearing, 2-hp electric motor or oil engine

Welding machine, sheet cutting machine, jig and fixture

Unit Cost: Mincing machine: Rs 15000/- ; Biogas reactor: Rs 10000/-





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POWER OPERATED GRAIN WINNOWER

This machine is utilized for efficient cleaning of various grains during harvesting, such as paddy, wheatcereals, and pulses, with low energy input. Winnowing capacity is 2000 kg/hr, in case of paddy and iconsumes 375 watt/hr energy. The winnower operates with a .5 hp electric motor or engine.

Product Feature

The device operates with two specific air jets. The upper air jet fluidizes the unclean grains, while thelower air jet carries the light materials to a distant place leaving behind the heavy grains. A blower isused for supply of air to the nozzles to create the jets. The mechanism ensures a higher degree ofcleaning of a variety of grains.


Mild steel angle, steel sheet, bearing, V-belt, .5hp electric motor or oil engine

Welding machine, sheet cutting machine, jig and fixture

Unit Cost: Rs 10,000/-





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LOW COST GLAZING (GLASS COATING) OF TERRACOTTA

It is a process for glazing or glass coating on terracotta products, such as roof tiles, floor tiles,handicrafts, earthenware etc., by using waste soda glass. A negligible amount of lead oxide is used fomelting the glaze material at low temperature (below 9000C) in the Queen kiln a product of IMMTused for the purpose of sintering a variety of terracotta and pottery material. Glazing improves the lusteand life of terracotta and makes the products water proof.

Product Features

The frit is initially prepared from broken glass pieces, and is then mixed with borax and lead oxide togrind in a ball mill. The glaze mixture is coated over terracotta using water and fired in the Queen kilnfor melting the glaze at 900oC.


Broken glass bottles, borax and lead oxide

Small ball mill, low cost coal fired furnace and Queen kiln

Unit Cost: Rs.0.50 Paisa per sq ft.




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Rural Technology Brochures