DESIGN AND DEVELOPMENT OF SCREW-PRESS BRIQUETTING MACHINE USING

KAPENG BARAKO (COFFEA LIBERICA) PULP FOR THE COFFEE FARM IN TIPACAN,
LIPA CITY.

Andal, Vergel Joseph V.

Laroza, Lorenzo R.
Valencia, Lyka Mariz B.
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND

Introduction
Objectives of the Study
OBJECTIVES OF THE STUDY
The main objective of the study was to develop a carbonized coffee pulp
based briquetting machine.
Specifically, it aims to:
1. Design and develop a carbonized coffee pulp based briquetting machine
for biochar production using locally available materials considering the
following:
1.1 system components; and
1.2 material specifications.
2. Fabricate the carbonized coffee pulp based briquetting machine taking into
account the established design specifications
3. Conduct carbonization process testing to establish the following
parameter:
3.1 carbonization time.
4. Conduct preliminary testing of the fabricated machine to establish the
following parameters:
4.1 best proportion of water, raw material, and binder;
4.2 mixing capacity;
4.3 mixing speed;
4.4 mixing time;
4.5 operating temperature; and
4.6 extrusion speed.
5. Evaluate the performance of the machine in terms of:
5.1 mixing rate
5.2 briquetting rate;
5.3 production rate;
5.4 percent yield; and
5.5 energy efficiency.
6. Evaluate the properties of the briquetted coffee pulp in terms of:
6.1 physical properties
6.1.1 dimensions;
6.1.2 bulk density; and
6.1.3 friability.
 6.2 chemical properties
6.2.1 calorific value;
6.2.2 ash content;
6.2.3 volatile matter;
6.2.4 fixed carbon; and
6.2.5 moisture content.
7. Evaluate the effectiveness of the briquetted coffee pulp through
water boiling test in terms of thermal efficiency and compare with LPG
as fuel.
8. Develop an operational and maintenance manual of the developed
coffee pulp briquetting machine.
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND

Introduction
Objectives of the Study
Conceptual Framework
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND

CHAPTER II
REVIEW OF RELATED LITERATURE

Conceptual Literature
Research Literature
Synthesis
Synthesis

• The briquetting technology that was considered and chosen is the screw type
press briquetting machine, which biomass is extruded continuously by a screw
through a taper die, influenced by the from the study “Biomass Briquetting:
Technology and Practices”.
• Despite the similar information found on existing and relevant studies from
this study on coffee pulp material, it is the actual production of briquettes by
carbonized agricultural waste material briquetting machine.
• One of the strong points to support this study is the usefulness and
functionality of successful briquetting technology even though different
methods and processes were used, results show that quality standard output
remains.
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND

CHAPTER II
REVIEW OF RELATED LITERATURE

CHAPTER III
DEVELOPMENT METHODS AND PROCEDURES

DEVELOPMENT METHODS AND PROCEDURES
• Research Design
• Development Stage
• Design Stage
• Fabrication Stage
• Preliminary Testing Stage
• Performance Testing Stage
• Experimental Testing Stage
• Preparation of Raw Materials
CHAPTER III
Methods of Testing
• Method of Determining the Best
Proportion of Coffee pulp, Wheat bran, and
Water.
• Method of Determining Mixing Capacity
• Method of Determining Mixing Speed
• Method of Determining Mixing Time
• Method of Determining Die Temperature
• Method of Determining Extrusion Speed
 CHAPTER III
DEVELOPMENT METHODS AND PROCEDURES

Final Performance Testing Methods of Testing of Properties of Briquettes

• Method of Determining • Method of Determining Dimensions
Mixing Rate • Method of Determining the Bulk Density
• Method of Determining the • Method of Determining the Friability
Briquetting Rate • Method of Determining the Calorific Value
• Method of Determining • Method of Determining the Ash Content
Production Rate • Method of Determining the Volatile Matter
• Method of Determining • Method of Determining the Fixed Carbon
Percent Yield Content
• Method of Determining • Method of Determining the Moisture Content
Energy Efficiency
Evaluation of the Effectiveness of the Carbonized
Coffee Pulp Briquettes Using Water Boiling Test
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND
CHAPTER II
REVIEW OF RELATED LITERATURE

CHAPTER III
DEVELOPMENT METHODS AND PROCEDURES

CHAPTER IV
DEVELOPMENT OF THE PROTOTYPE, EXPERIMENTAL RESULTS AND DISCUSSION
Schematic Diagram
• Operational Procedures
• Collection and Preparation of Raw Materials
• Preparation of Binder
• Preparation of Mixture
 Preliminary Testing Results

50:30:20
60:30:10

70:20:10
Determination of the Best Proportion

Established Values
Ratio
Capacity
Mixing Speed
Mixing Time
Extrusion Speed
Die Temperature
Carbonization Time
Determination of the Capacity of Mixer

Established Values
Ratio 50:30:20
Capacity
Mixing Speed
Mixing Time
Extrusion Speed
Die Temperature
Carbonization Time
Determination of Mixing Speed

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed
Mixing Time
Extrusion Speed
Die Temperature
Carbonization Time
Determination of Mixing Time

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed 1000 rpm
Mixing Time
Extrusion Speed
Die Temperature
Carbonization Time
Determination of Die Temperature

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed 1000 rpm
Mixing Time 1 minute
Die Temperature
Extrusion Speed
Carbonization Time
Determination of Extrusion Speed

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed 1000 rpm
Mixing Time 1 minute
Die Temperature 130 °C
Extrusion Speed
Carbonization Time
Determination of Carbonization Time

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed 1000 rpm
Mixing Time 1 minute
Die Temperature 130 °C
Extrusion Speed 120 rpm
Carbonization Time
Summary of Results of Preliminary Testing

Established Values
Ratio 50:30:20
Capacity 3000 g
Mixing Speed 1000 rpm
Mixing Time 1 minute
Die Temperature 130 °C
Extrusion Speed 120 rpm
Carbonization Time 60 min
Final Testing Results of Machines Parameters
Performance Testing Results
Power Consumption
Energy Efficiency
Water Boiling Test Results
Thermal Efficiency of Coffee Pulp Briquettes
 CHAPTER V
SUMMARY OF FINDINGS,
CONCLUSIONS AND
RECOMMENDATIONS
 CHAPTER I
THE PROBLEM AND ITS BACKGROUND
CHAPTER II
REVIEW OF RELATED LITERATURE

CHAPTER III
DEVELOPMENT METHODS AND PROCEDURES

CHAPTER IV
DEVELOPMENT OF THE PROTOTYPE, EXPERIMENTAL RESULTS AND DISCUSSION

CHAPTER V
SUMMARY OF FINDINGS, CONCLUSIONS AND RECOMMENDATIONS
Summary of Findings
This study aimed to design and develop a heater screw press carbonized coffee
pulp briquetting machine that can be used to produce briquettes as an alternative fuel
from the mixture of coffee pulp, wheat bran, and water. The following were the
findings based on the objectives:
1. The carbonized coffee pulp briquetting machine was developed and designed using
locally available materials to produce briquettes as an alternative source of fuel.
2. The carbonized coffee pulp briquetting machine consisted of , heater, induction
motor, screw press extruder, variable frequency drive (VFD), gear motor, body frame
and mixer. The specifications of the system components were detailed in each figure.
3. In preliminary testing, the best proportions were simply mixed. The 3 kilograms of
mixture with the ratio, 50:30:20 weight percentage of water, coffee pulp, and wheat
bran, were the only proportions that could produce the optimum number of briquettes
and best quality. Furthermore, the established mixing time was 1 minute at a speed of
1000 rpm, and the operating temperature was 130°C.
4. The machine had an average mixing rate of 30,000 g/min with an average
briquetting rate of 11.87 pcs/min, an average production rate of 0.9992 pcs/min,
and an extrusion rate of 1.03 pcs/min. The machine had a computed average
percent yield of 78.88%, the net energy efficiency of the coffee pulp briquettes
was 132.38%, and the average total power consumption was 3.705 kWh/day
5. In the appraisal of the physical properties of the coffee pulp briquettes, the
briquettes had an average density of 0.7799 g/cm³ and average friability of 91.13%
respectively. The average dimension of the produced briquettes were 1.49 cm
diameter and 3cm in height. In the assessment in the chemical properties, the
produced coffee pulp briquettes had an average calorific value of 4749 cal/g,
moisture content of 10.6% and ash content 9.4%.
6. The project was able to develop a briquetting machine that uses a screw press
extruder which compresses the mixture of water, coffee pulp, and wheat bran as
alternative energy sources to operate the machine to form the final product which
was the briquettes.
Conclusion
The following conclusions were derived bases on the findings and from the
results obtained in the study:
1. It was concluded that for the better efficiency of the machine; the use of
necessary specifications of the equipment components to simultaneously operate
the machine.
2. It was concluded that determination of the value for system components will
come up for the better use of the available materials and its specifications.
3 It was concluded that there was a need to establish the best proportion of the
mixture and the other operating parameters to produce the best quality of
briquettes.
4. It was concluded that there was a need to evaluate the mixing rate, briquetting
rate, production rate, extrusion rate, and percent yield to test the performance of
the machine.
5. In preliminary testing, the operating parameters were established, the
produced briquettes were tested to evaluate the physical, mechanical, and
chemical properties.
6. It was concluded that the coffee pulp briquette can be produced and
become a source of alternative energy/fuel.
7. It was essential to use the proper operation and maintenance manual to
prolong the operating life of the machine, and the best quality of briquettes
produced.
Recommendations
Based on the findings and conclusions evaluated, the recommendations are as
follows:
1. The mixer may be equipped with a gear motor instead of an induction motor to
overcome the load bearing of the mixture while undergoing mixing operation.
2. The mixer may be modified with a circular housing to maximize mixing efficiency
and the angle of inclination of the mixing blades to further increase mixing efficiency.
3. The passage from the mixer to the extruder may be widened in order to increase
production rate.
4. The molder and compactor may be equipped with an pneumatic sensor cutter to
decrease human contact and error while undergoing machine operation.
5. It is suggested that other possible agricultural waste as raw materials or a binder
may be assessed to have another source and effective briquettes produced
6. It is suggested that other ratios may be explored that can increase the
number of briquettes produced and the best quality of briquettes.
7. Thorough safety precautions of the machine and whole briquetting process
should be known to the beneficiary to maintain functionality of the machine
and to avoid any accidents that may occur while undergoing operation.
To GOD be the Glory.