Gasifier for crumb rubber drying

Ideal Crumb Rubber FactorySreekrishnapuram, Mannarkkad

Present Scenario in operation

Optimisation of working results Increase in Productivity. Reduction in cost of Production. Reduction in waste.

Cost components Raw Material cost - Not controllable Cost of drying the rubber Cost of Electrical energy Other costs of wages, Maintenance etc.

Drier Cost Component

Type of drier : Continuous trolley type tunnel dryer

Fuel Consumption : 22 lts / Hr of HSD or SKO Specific fuel consumption : 36.6 Lts per Ton of crumb rubberAverage fuel cost : Rs. 18 per LtrCost of operation of dryer : Rs.396 /hour of operation

Rs.659/- per ton of rubber dried

Fuel cost reduction in the drier was the primary objective to reduce the overall cost of final product

Process towards cost reduction

Non conventional energy ? Consultant in the area? Seminars by MNES / Agencies Manufacturers of gasifier Site Visits Technology provider

Analysis of technology Economy of operation. Safety of installation as well as people working. Ease of Maintenance. Trouble free performance. Continuous operation. Lower down time for maintenance. Low emission of tar or any other pollutants.

After visit to IISc, Bangalore and various installations the

order was placed on Bioresidue Energy Technology (P) Ltd.

Positive features we noticed

Flame trap to arrest flame flash back. PP valves to ensure long and trouble free operation. Brick lined inner and SS construction. Servicing platforms to facilitate easy servicing. Audiovisual alarms for critical parameters. Oxygen sensor-Offline to ensure safety of oxygen

ingress. Screw conveyor for ash removal & Biomass flexibility. Technological back up from the premier institution Indian Institute of Science,Bangalore

Maintenance of the gasifierTotal hours of operation : 5000 HoursTotal No. of stoppages : 6Continuous operation : Up to 1250 hoursReplaced components : Air nozzlesCost of maintenance : Rs.28,300/- till datePost supply additions : Flame failure system

Timers for screw operation

Post supply replacements : Valve – 1 No.Cost of maintenance : Rs. 5=66 per hour

Economics of operationOperation of the gasifier : 5000 Hours (98% up

time)Average cost of biomass : Rs. 2=50 per kgBiomass consumed : 347279 kgsFuel oil replaced : 109846 ltsHSD Cost (W/O Gasifier) : Rs. 19,77,228Biomass Cost : Rs. 8,68,198Additional power cost : Rs. 79,888Net Saving : Rs. 10,29,143Savings as percentage : 52%