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International Journal of Forestry and Wood Science

Vol. 7(1), pp. 067-075, February, 2020. © www.premierpublishers.org. ISSN: 2167-0465

Research Article
Remodeling a Manually Operated Bio Briquetting Machine for
Bio Briquetting of Dry Chir Pine Needles in Western Himalayan
Region
*1Kumar Joshi, I.F.S; 2Vinay Sharma
1Post Doctoral Fellow, 2Professor, Department of Management Studies, I.I.T Roorkee. Uttarakhand, India

Briquetting of organic waste like wheat straw, peanut shell, coconut fibers, rice husk, maize cob and various
other agricultural residues is a common practice in India and abroad. Generally briquetting process is done
by application of heat and pressure through electrically driven machines. This paper accounts for
developing a bio briquetting machine in horizontal orientation and a comparative study between two
models of manually driven bio briquetting machine for a harmful forest bio residue of Western Himalayas
named as dry and fallen pine needles. One of the authors of this paper has successfully designed and
manufactured these two types of manually driven forest bio residue briquetting machine in vertical and
horizontal orientation. These machines are designed to reduce the use of fossil fuels and promote clean
and green energy. The uniqueness of the paper is also reflected by adopting grass not level execution
strategy for addressing climate change issue and creating livelihood opportunities for the communities
through converting a harmful forest bio residue into a useful resource for clean energy under social
entrepreneurship skills. It is further added that such an intervention will avoid devastating forest fires which
are primarily initiated by huge quantity of dry and fallen pine needles lying on the forest floors. A manually
operated bio briquetting machine finds its larger acceptability for a eco fragile, fire prone, chir pine forest
areas of Western Himalayas by eliminating fire hazards as well as providing direct economic benefits to the
villages through the sale of bio briquettes.

Key words: Western Himalaya, Pine needles, Manual briquetting machine, Livelihood opportunities, Forest fires.

ARTICLE HIGHLIGHTS

• This article basically aims at developing an indigenous and an appropriate technology in reducing the forest fire
hazards in Western Himalayan region.
• The article gives a complete picture of manually operated bio briquetting machines which are capable of converting a
loose bio mass into briquettes.
• The main author of the article is a field practitioner for over last 28 years in natural resource management and really
felt an urgent need to address environmental issues because of repeated forest fire in Western Himalayas. While
doing so, creation of sustainable livelihood options for the communities from waste and harmful dry and fallen pine
needles is also kept in mind.

INTRODUCTION
Energy has been the driving force behind the process of 6% of the world’s primary energy. Indi’s per capita energy
economic development. Greater access to energy has consumption lags that of the world’s middle-income
fostered economic growth as well as other indicators of countries. Figure 1 shows per capita primary energy
human development. India has a per capita energy consumption of upper middle-class countries.
consumption of only about one third of the global average.
India’s per capita energy consumption equals 0.6 tonne of *Corresponding Author: Dr. Kumar Joshi, I.F.S, Post Doctoral
oil equivalent (toe) as compared to global per capita Fellow, Department of Management Studies, I.I.T Roorkee.
average of 1.8 tonne of oil equivalent. Though India Uttarakhand, India. Email: kapilkjoshi@rediffmail.com.
accounts for 6% of world’s population it uses only around Co-Author 2Email: vinayfdm@iitr.ac.in

Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Joshi and Sharma 068

India, the world’s largest democracy, catering about 18%


of world’s population of 1369 million is bound and
determined to showcase unusual and remarkable
performance on 2030 Agenda for Sustainable
Development, to take out its inhabitants out from income
poverty as well as energy poverty scenario, to shine
globally renewable energy framework and to promote
indigenous and appropriate technologies for
environmental supportability at grass not levels. In doing
so, there are some direct hindrances, where we are truly
not able to defend on global or international framework.
One amongst them is the gradual degradation of Western
Himalayan ecology because of rampant forest fires in chir
Within this consumption, access to clean fuel is unevenly pine forests. The Himalayas is recognized for its
distributed spatially in rural vis-à-vis urban areas and ecosystem services to the Asian region as well as to the
socio-economically when seen across income groups. world at large for maintaining slope stability, regulating
India, therefore, needs to quadruple its per-capita energy hydrological integrity, sustaining high levels of biodiversity
consumption to meet the rising aspirations of its citizen. and human well-being.
This will also enable India to achieve the human
development status of an upper-middle-income country. Himalayan mountain system is one of the most fragile
ecosystems in the world because of its inherent tectonic
India has also strived to increase the share of energy from and geological settings (Valdia, 1983)). It is known to have
sustainable sources. The share of renewable in total a rich storehouse of large biodiversity ranging from tropical
generation has increased from 6 per cent in 2014-2015 to forest, sub-tropical chir pine, temperate forest of broad leaf
10 per cent in 2018-2019 (GOI, 2019 1a). In addition to this and conifer to subalpine and alpine meadows. During the
India’s energy needs have been complemented by efforts recent past, the Himalayan bio resources have come
to use energy efficiently. The overall electricity savings due under great stress due to population pressure, resources
to adoption of these energy efficiency measures is exploitation and various developmental activities which
estimated at 7.21% of the net electricity consumption in have resulted in the reduction in biodiversity and
2017-2018 (GOI, 2019 1a). degradation of natural ecosystem. Among various causes,
the occurrence of frequent forest fires has of late emerged
India’s efforts for climate change mitigation through use of as one of the severe threats for recession of biodiversity,
renewable energy sources has placed it globally 4th in wind natural regeneration, productive capacity, soil fertility,
power, 5th in solar power and 5th in renewable power moisture, wildly and forest produce. This has adversely
installed capacity (GOI, 2019 1b). affected the rural economy an ecosystem as a whole
(Kimothi, 1998). According to forest survey of India (FSI),
The 2030 Agenda for Sustainable Development and its 17 during the period of 6th five-year plan over 572417 area of
Sustainable Development Goals (SDGs) adopted by world India’s forest was affected by forest fire amounting to a
leader in 2015 presents a roadmap for future development loss of over half a million USD (Anonymous,1989). A
trajectory to all nations with focus on poverty eradication, recent report on the status of forest reveals that on an
environmental sustainability, peace and prosperity. average 53% of the forest cover in the country is affected
Indian’s development agenda has for long been based on by fire, and such incidents are more severe in the Western
principles that are closely related to those that have been Himalayan region of India which is predominantly rich in
propounded in the 2030 Development Agenda. India has chir pine (Anonumous, 1995).
been preserving to address the climate challenges along
with other developmental imperatives. India has been Uttarakhand is a state of union of India in the western
making substantial additions to its installation of renewable Himalayan region. About 71% of its total geographical area
power capacity. Increasing growth rate and rapid is under forest. This area comprises thousands of species
urbanization in India have spurred the demand for natural of trees, shrubs, herbs and climbers along with equally
resources (GOI, 2019 1c). India’s seriousness about large no of faunal species (Anonymous, 2013). Chir pine
sustainability in energy sector could be seen by its various is a major species found in this region starting from 1000
energy efficiency programmers which witnessed meters to 2000 meters under a gross estimation over half
exceptional performance in terms of reducing energy a million hectare of forest area in Uttarakhand is
consumption thereby leading to lower greenhouse gas predominantly shadowed with chir pine trees (UFD, 2012-
emissions and cost savings. According to Bureau of 13). Forest of this area are used variously for fodder, fuel
Energy Efficiency Study, overall, this saving has resulted wood, timber, litter, timber and several other non-timber
in total cost savings worth Rs. 53.000 crore in 2017-2018 forests produces (Ram et al.,2004). People living in this
and contributed in reducing 108.28 million tonnes of CO2 state have less employment opportunities because of
emission (GOI, 2019 1d). rough terrain, adverse climatic conditions and developing
infrastructure.
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Int. J. For. Wood Sci. 069

Chir Pine trees have a tendency of shedding its leaves 1995), paper mill waste (Yaman et al., 2000), peanut shell,
every year in the month of January to May. These dry and coconut fibers, palm fruit fibers (Chin & Siddiqui, 2000),
fallen pine needles are highly inflammable and contain 18- rice straw, rice husk and maize cob (Wilaipon, 2007).
20 mega joules of energy per kg of its mass which is higher Process parameters like densification pressure, particle
than that of word, sawdust and fuel oil (Safi, 2002). In an size, moisture content and temperature are different for
estimation by Forest Research Institute, Dehradun over a different raw material available for briquetting. Lignin of the
million tonnes of dry pine needles fall every year on the biomass melts at high temperature and pressure which
forest floor of Uttarakhand (UFD, 2010). These needles directly affect strength characteristics of the bio briquette.
are extremely combustible and repeatedly course Densification is influenced by compaction temperature,
hazardous forest fires in the summer months. Burning of compaction pressure, compaction velocity, moisture
pine needles is a big source of atmospheric carbon. This content and particle size distribution (Mani et al., 2006)
also leads to soil erosion, land degradation, dryness, loss (Rhen et al., 2005). An optimum process parameter is vital
of young plantation and damages to life and property of the for a good quality bio briquette as densification process
human beings. parameters directly affect change in volume, durability,
density and strength of the briquette (Kaliyan & Morey,
Pine needles are abundantly available in the hilly region of 2009).
Himalayas on thermal decomposition they generate gases
such as light volatiles, carbon monoxide, carbon dioxide, Different types of machine are available in the briquetting
hydrogen and other organic vapors. Since pine needles industry globally. Europe and United States of America
pose serious threat to forests and forest fires, their have perfected the reciprocating ram- piston technology
collection and disposal for energy recovery is a very while Japan has independently invented and developed
attractive proposition (Safi et al., 2004). screw press technology (Grover & Mishra, 1996).
Briquettes produced by a piston press are completely solid
while screw press briquettes on the other hand have a
LITERATURE REVIEW concentric role which gives better combustion
characteristics due to a larger surface area (Tumuluru et
Biomass briquetting is the process of densification of loose al., 2010).
biomass to improve its fuel and handling characteristics. It
increases the volumetric calorific value and reduces At present, these high-pressure technologies are widely
transportation cost and storage space requirement as used for briquetting. China is also producing large scale
compared to raw biomass. Briquetting produces a uniform, briquetting plants (Tumuluru et al., 2010). Cost of such
clean and stable fuel (Granada et al., 2002). By briquetting, plants is very high. For a unit producing about 2000 tonnes
bulk density of loose biomass can be increased from 40 to briquette in a year roughly cost a little over US D 1,00,000
200 kg m-3 to 600-1200 kg m-3which would reduce the which excludes the cost of the land (Fergunson, 2012). In
storage requirement significantly (Adapa, 2009). Biomass addition to large cost of plant and machinery for a
briquettes have been hailed as a potential means of briquetting industry various technical constraints like high
upgrading the raw biomass waste and providing a wood as wear and tear in screw extrusion briquetting technology,
well as fossil fuel substitute that could potentially by use in very high electricity bills even up to 15% of the total
domestic cooking applications and industrial applications. production cost (Grover & Mishra, 2010), inability of local
Biomass briquetting in many developing countries has for artisans to ensure smooth running and maintenance of the
years been synonymous with densification of sawdust and machine, experts supervision for installation and site
other agro residues (FAO, 1990). Over the past many specific variations in the plant and machinery have
decades, developing countries are promoting use of resulted in numerous failure of the machines and inhibited
electricity and fossil fuel energy to transform the life of poor extensive exploitation of bio briquettes as fuel (Kaliyan &
household (IEA, 2002). However, it is estimated that over Morey, 2009).
2.7 billion people rely on traditional biomass like wood,
charcoal and dung and half billion on coal for cooking and It is generally agreed upon that bio briquetting may be
space heating despite having access to some form of treated as a suitable business case for a substitute fuel.
electricity (Bravo, 2008) (Karekezi et al., 2008). This is But challenges like inability of producers to access
largely because electricity and Liquefied Petroleum Gas appropriate technology for commercially producing quality
(LPG) have become very expensive and unaffordable by briquettes are widely existing (Clancy, 1995) (Hood, 2010).
the majority of low-income earners. Use of wood, coal and There is therefore acute need to address high cost and
unprocessed biomass by a huge population in developing operational problems in order to ensure that commercial
countries contributes not only indoor air pollution but also briquette production result in successful enterprises.
largely affects climate change issues. Locally manufactured briquetting machines may be a
leverage point towards widespread adaptation of briquette
Bio briquettes are produced from any lingo-cellulosic plants, increasing sales and improving the quality of
organic material. Most widely used raw materials for briquettes. Moreover, very high consumption of electricity
briquetting are saw dust, wheat straw (Wamukonya, is also not desirable as the electricity is driven from mainly
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Joshi and Sharma 070

fossil fuel sources which may make the whole process of


briquetting as a very high carbon positive venture (GVEP,
2011).
In order to create a mass movement towards reduction in
use of fossil fuels, proper utilization of agricultural and
forest bio waste, creating livelihood options for weaker
sections of the society and addressing various climate
change issues, innovations in locally made bio briquetting
machines are really needed specially in developing
countries like India. Locally made bio residue briquetting
machine must have following traits in order to execute
briquetting venture at grass root levels.

• Easy handling, low cost, less maintenance.


• Manually driven.
• No carbonization or pyrolysis process is needed.
• Components of the Vertical briquetting machine
• No additives or binding is needed.
• Site specific design and easy to transport.
This machine has following main components:
• May convert a broad range of feedstock into briquette. ➢ Oil sump fitted with 2 levers and hydraulic oil.
• Low noise and easy briquette discharge. ➢ Pressure valve on the sump to bring the oil back
inside the sump.
METHODOLOGY ➢ Mild Steel pipes connected to oil sump and
compaction and ejection cylinders.
In designing a vertically and horizontally aligned manually ➢ Main valve 1 and 2 for inflow and outflow of the oil.
operated bio briquetting machine, unknowingly a ➢ Compaction cylinder (85 mm) along with spring
continued evolutionary process with reflexive linkages as and piston assembly.
given by the various stake holders was seen inherent in ➢ Die and mould assembly.
methodological frame work. In addition to this knowledge ➢ Ejection cylinder (85 mm) along with spring
of structural engineering, hydraulics, material science and assembly.
pine needles chemical properties was deeply studied while ➢ Measuring scale, pressure gauge.
actually manufacturing the two machines.
• Line diagram and operation of vertical briquetting
Manually operated bio briquetting machines in vertical machine
orientation and horizontal orientation were designed and
developed at Alternate Hydro Energy Centre, Indian The Machine drawing is given in figure 3. The machine
Institute of Technology, Roorkee, Uttarakhand, India. operates on the basic fundamental of hydraulics. The
machine consists of an oil sump of about 7 liters oil
OBJECTIVE capacity. The raw material is poured in the die. Valve 2
is closed and lever no.1 is operated to pump the oil into
The main objective of this study is to develop, present and compacting cylinder. A constant watch is kept over the
replicate an affordable and marketable manual briquetting pressure gauge fitted near the valve no 1. Depending
machine based on forest bio residue resource as a upon the type of raw material the pressure is built up to
sustainable mode of renewable energy and livelihood 70-150 kg/cm2. Once the pressure is built up and the
option to the communities. piston is moved well inside the die filled with raw
material, valve no.1 is closed and valve no. 2 is opened.
Once again lever no. 2 is operated and the backward
DISCUSSIONS pressure works on the ejection cylinder facilitating
smooth withdrawal of the bio briquette from the die.
The discussion part of this paper includes general Though the working procedure seems to be very simple
description of horizontal and vertical type of briquetting but sequential opening and closing of the valve is very
machine and the time study conducted over these crucial. Any expropriate faction may lead to oil spill,
machines for optimizing the briquetting time. bursting of hose pipes, slacken nut bolts, piston jam
and sticking of the spring of the ejection assembly.
❖ Vertical Briquetting Machine
This machine was finally developed and successfully
tested in the year 2016 at Alternate Hydro Energy
Centre, IIT Roorkee workshop. The actual brick making
photograph of the machine is shown figure 2.
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Int. J. For. Wood Sci. 071

average time for each step was recorded and then average
time was taken. It was observed that a total of 125 seconds
were taken by the machine to make a briquette of about 8
to 10 grams. Table 1 depicts the activity wise time taken
to manufacture a briquette from pine needles by this
machine.

Table 1: Time study for vertical briquetting machine

• Scope for improvement of a vertical briquetting


machine

Though the basic fundamental of densification of the


loose biomass through manually operated hydraulic
pressure application got well established in this
machine but many more scopes for appropriate
improvement in this machine were realized. This
machine has following limitations which were totally
blown away in the next version of a manually operated
bio briquetting machine in horizontal orientation.

➢ Output efficiency of the machine is low and may not


• Time study on a vertical briquetting machine be able to deliver minimum wage rate guarantee to
This machine has following sequence of operations: the worker for 8 hours of working a day.
➢ Weight of the briquette manufactured is less. It may
Loading of raw material in the die, close valve no. 2, pull be optimized by increasing the dig of the die but this
and push lever 1, open valve 1, build up the desired will further change the whole machine design as the
pressure, close valve no.1, open valve no. 2, push and compacting pressure has to be increased.
pull lever no. 2 till the briquette is ejected from the die. ➢ Hydraulic fluid if contaminated will spoil the various
A flow diagram of the briquetting process on this piping and piston cylinder assembly.
machine is shown in figure 4. ➢ The weight of the machine is as high as 300 to 350
kg. It is not easy to be transported on hilly terrain as
it is fabricated as a single individual unit tightly
fastened by nuts and bolts.
➢ Operating the machine becomes very tiring for the
operator as the machine is only hand operated.
➢ This machine cost about USD 1500 per unit if
manufactured locally.

❖ Horizontal briquetting machine

It took almost over 2 years to modify and develop a


new briquetting machine in which all efforts were made
to eliminate the limitations of the previous machine.
This machine was also developed in the Alternate
Hydro Energy Centre, Indian Institute of Technology,
Time taken to make one single briquette was recorded by Roorkee, Uttarakhand in the year 2019. The actual
a stop watch. A total of 100 briquettes were made and the machine photograph is shown in figure 5.
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Joshi and Sharma 072

➢ Open the pressure release valve, the plunger


withdraws automatically.
➢ Push the briquette with a stick from the die.

Fig. 6: Design of horizontal Briquetting Machine

• Components of the Horizontal briquetting


machine

The Machine has following main component:

➢ Horizontal bench reinforced with heavy mild steel


angles to give extra strength to the machine.
➢ Hydraulic oil sump fitted with one lever.
➢ Pressure on-off wall, pressure gauge.
➢ Horizontal piston - cylinder assembly.
➢ Horizontal die – mould assembly.
➢ Stopper plate, hopper, hose pipes.
➢ Foot pedal connected with hand lever.

• Line diagram and operations of the Horizontal Fig. 7: Design of horizontal Briquetting Machine (top view)
briquetting machine
• Problems encountered while developing a
The machine design is shown in figure 6 and figure horizontal machine
7. This machine also operator on the basic principle of
hydraulics. The machine operations are as follows: During the process of designing a horizontal
briquetting machine, the biggest problem encountered
➢ Charge the hopper with dry and crushed pine was repeated failure of the machine bench over which
needles horizontal piston-cylinder assembly was mounted. The
➢ Shut the stopper plate. main cause of the bench failure was excessive
➢ Fill the niche of the die with pine needles by raising pressure of the level of 2500 to 3000 psi coming over
the side of the hopper. it through hydraulic unit. A further reinforcement was
➢ Close the slide. provided over the bench in the form of heavy mild steel
➢ Close the release value of the pump. angle rods strongly welded over the bench structure in
➢ Start pumping in reciprocator manner by using lever order to avoid its bending. Similar problem was faced
(hand and foot) attached to the hydraulic pump. The in horizontal die mould assembly which got displaced
plunger attached to the pump pushes pine needles under excessive pressure causing damages to piston
and starts compressing it. also. This problem was tackled by removing nut bolt
➢ Briquette is made inside the die with a pressure assembly used to fasten the die-mould system over
ranging 100 to150 kgf/cm2. the bench and by providing a welded die-mould
assembly directly over the machine bench.
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Int. J. For. Wood Sci. 073

• Time study on the Horizontal briquetting machine may switch over to hand as well as to foot as per
his operational.
This machine has following sequence of operation: ➢ Cost of the machine comes about USD 1000 per
Loading of the raw material in to the die, close the unit, if manufactured locally.
release valve and ensure sufficient pumping to ensure ➢ Manually operated and horizontally aligned bio
briquetting, open the release valve, wait for the piston briquetting machine has few more advantages
to move back and eject the briquette with the help of like low operating time, easily transportation, less
an ejecting handle. This machine has almost half of maintenance, less weight, dual operating feature
the operations as desired in the previous briquetting (hand and foot), multiple uses and low cost as
machine. compared to manually operated and vertically
aligned bio briquetting machine.
A flow diagram of the briquetting process is show in
figure 8. Figure 9 depicts a consolidated sequence of operations
on both the machines in pictorial form.

Time taken to make a single briquette was recorded


by a stop watch. A total of 100 briquettes were made
and the average time for each step was taken. It was
observed that a total of 85 seconds were taken by the
machine to make a briquette of about 70 to 80 grams.
Table 2 depicts the activity wise time taken to
manufacture a briquette from pine needles by this
machine.

Table 2: Time study for horizontal briquetting machine

1. Advantages of the horizontal briquetting machine


over a vertical briquetting machine
➢ Output efficiency of the machine is quite high and
is completely able to guarantee a minimum wage
rate to a worker as etc over vertically aligned bio
briquetting machine. Fig. 9: Working Comparison of Pine Briquette machines
➢ Weight of the briquette manufactured from this
machine is as high as 80-90 grams. This size and
weight is fair enough for transportation and for CONCLUSION
various commercial uses.
➢ Movement is hydraulic fluid is comparatively very An inclusion of an appropriate technology may turn
less so chances of damages to piston-cylinder superior to an advanced technology, depending upon the
assembly is quite low. specific requirement of the area. Though many mega bio
➢ Weight of the machine is of the order of 175 to briquetting plants are available and working but the option
200 kgs, which increases its portability to hilly and of using forest bio residue in these plants was never
rough terrain. explored. It was primarily because of the excessive cost
➢ Operating the machine is quite comfortable as it involved in transporting the loose bio residue from the site
operates by hand as well as by foot. An operator of its origin to the factory site. It was found that only 1 to 2
Remodeling a Manually Operated Bio Briquetting Machine for Bio Briquetting of Dry Chir Pine Needles in Western Himalayan Region
Joshi and Sharma 074

tonne of loose and dry fallen pine needles could be Food and Agricultural Organization (1990) The briquetting
transported in a truck, which makes this venture highly of agricultural waste for fuel: Environment and Energy
uneconomical for mega bio briquetting plants. An series
appropriate technology in the form of a manually operated Global Village Energy Partnership (2011) Kenya Briquette
bio briquetting machine to convert forest bio residue into industry study. Global Village Energy Partnership,
useful briquettes at the place of it’s origin has given a Nairobi.
strong substitute of mega bio briquetting plants for Government of India (2019) Ministry of Finance Economic
Western Himalayan region. Once densified at it’s place of survey 2018-19, Chapter 9, vol 1, 164
origin, a total of 6 to 7 tonnes of bio briquettes could be Government of India (2019) Ministry of Finance Economic
easily transported to it’s end users. This phenomenon of survey 2018-19, Chapter 9, vol 1, 175
transporting 6 to 7 tonnes of bio briquettes in a single go Government of India (2019) Ministry of Finance Economic
from a hilly terrain up to the consumer’s end not only make survey 2018-19, Chapter 5, vol 2, 104
this venture commercially viable but also provide ample Government of India (2019) Ministry of Finance Economic
scope for livelihood creation to the local communities. survey 2018-19, Chapter 9, vol 1, 172
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International Energy Agency (2002) Energy and Poverty.
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