Joint UNDP/World Bank Energy Sector Management Assistance Program Activity Completion Report No. 062B/86 Country: ETHIOPIA Activity: AGRICULTURAL RESIDUE BRIQUETTING PILOT PROJECTS FOR SUBSTITUTE DOMESTIC AND INDUSTRIAL FUELS (VOLUME II - ANNEXES) DECEMBER 1986 Report of the joint JNDP/Wd Bank EneSy Sector Management Assistance Program This document has a restricted distribution. Its contents may not be disclosed without authorization from the Government, the UNDP or the World Bank. BNq SECTOR MGENT ASSISTARCB PROM * The Joint UNDP/World Bank Energy Sector Management Assistance Program (ISHAP), sturted,in April 1983,,assists countries in implementing the main investment *d policy recommendations of the Energy Sector Assessment Reports produced under another Joint UNDP/World Bank Program. ESMAP provides staff and consultant assistance in formulating and justifying. priority pre-investmee and investment projects and in providing management, institutional and policy support. The reports produced under this Program provide governments, donors and potential investors with the information needed to speed up project preparation and implementation. ESMAP activities can be classified broadly into three groups: - Energy Assessment status Reports: these evaluate achieve- ments in the year following issuance of the _original assessment report and point out where urgent action is still needed; - Project Formulation ,and- Justification: work designed to accelerate the preparation and implementation of investment projects; and - Institutional -and Policy Supporti this work a.so frequently leads to the identification of technical assistanc6 packages. The Program aims to supplement, advance and strengthen the impact of bilateral an4 multilateral resources already available for technical assistancelin the energy sector. Funeading of the Program The Program is a major international effort and, while the.core finance has been provided by the UNDP and the World Bank, important financial contributions to the Program have also been made by a number of bilateral agencies. Countries'-whiph have now made or pledged initial contributions to the programs through the UNDP Energy Account, or through other cost-sharing arrangements with UNDP, are the Netherlands, Sweden, Australia, Switzerland, Finland, United Kingdoi, Denmark, Norway, and New Zealand. Purther Information For further information, on the Program or to obtain copies of roompleted ESMAP reports, which are listed at the end of this document, please contact: Division for Global and OR Energy Strategy and Interregional Projects Preinvestment Div.-II United Nations Development Energy Department Program World Bank One Uilted Nations Plaza 1818 H Street, N.W* New Yorvy, N.Y. 10017 Washington, D.C. 20433 ETHIOPIA AGRICULTURAL RESIDUE aRIQUETTING PILOT PROJECTS FOR SUBSTITUTE DOMSTIC AND INDUSTRIAL FUELS (VOLUME II - ANNEXES) DECEMBER 1986 Annex 1:Detailed Financial and Economic Costing for Potential Briquetting Plants and Sensitivity Analyses of Key Parameters Annex 2: Chemical and Physical Analysis of Ethiopian Agricultural Residues Briquetting (TUO Report) Annex 3: Excerpts from Combustion Consultant's Report on Briquettes as an Industrial Fuel for Ethiopia (Consultant: Robert Chronovski; July 1985) Annex 4: Specifications for Major Equipment Annex 5: List of Recommended Equipment Suppliers for Briquetting Plants Annex 6: Supervising Engineer: Terms of Reference Annex 1 DETAILED FINANCIAL AND BCONONIC COSTING FOR POTENTIAL sRIQUETTING PLANTS AND SENSITIVITY ANALYSES OF KEY PAAMETERS (1985 figures) - I.- Table A1.1: DETAILED ECONOMIC AW FINANCIAL COSTINGS FOR PTENTIAL PILOT 8RIUETTINS PLANTS SUMIAltY TABLE AND MIER COST/TON(S) COSTAIMIT ENERGY(S1) FINANCIAL COST ECONOMIC COST FINANCIAL COST ECONOMIC COST MLIVERED FACTORY - DELIVERED FACTORY DELIVERE FACTORY DELIVERED FACTORY COFFEE DILLA-IUSK 71.695 37.035 61.965 41.809 3.630 1.675 3.138 2.117 COFFEE DILLA*Pt.P 92.858 58.196 82.046 61.870 4.006 3.012 4.24 3.202 COFFEE PARCHq-NEtI SITE 31.221 31.221 34.498 34,498 1.615 1.615 1.785 1.785 COFFEE PARCH.WERCATO 37.752 37.752 43.535 43.535 1.953 1.953 2.252 2.252 COTTON STALKS-AMASH 113.941 82.061 113.175 95.445 6.401 4.610 6,358 5.362 *IEAT STRAW-0IXIS 114.674 80.064 105.857 93.577 6.353 4.469 5.865 5.184 CON STALKS AND STOVER 140.341 106.461 144.655 122.033 7.525 5.616 7.756 6.543 PARAMETERS DISCOUNT RATE 100$ ELECTRICITY RATE (S/KW-H) 0.063 DIESEL RATE (SAITER) 0.374 PLANT LIFE% BUIlDMIN/PROIJECT (YRS) 20 GRIQUETTORS (YRS) 15 PLANT E9UIPMENT (YRS) 12 COLLECTION EUIPMENT (YRS) 8 TRANSFORIER/EMRATOR (YR) 8 SHADIOt FACTOtS/PRICES: FOREIGN EXrIlANE 1*330 UNSKILLED LABOR 0500 ELECTRICITY (S10f-H) 0.063 DIESEL (SALITER) 0.397 -2- Table A1.2: RESIDUE: COFFEE HUSK-DILLA CAPACITY: 5000.000 TONS ENERGY 19.750 ALL FIGURES IN '000' U.S. DOLLARS CAP. & OPER. COSTS ANNUALIZED COST ITEMS LIFE LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL (Yrs) I. CAPITAL COSTS A. CONSTRUCTION - SITE PREPARATION 20 11.600 11.600 1.363 0.000 1.363 BUILDINGS 20 65.800 19.100 84.900 7.729 2.243 9.972 HOUSING 20 0.000 0.000 0.000 0.000 SUB-TOTAL 77.400 19.100 96.500 9.091 2.243 11.335 B3 EQUI PNENT PISTON BRI, 15 172.000 172.000 0.000 22.613 22.613 SCREW BRIQ. 15 0.000 0.000 0.000 0.000 COLLECTION EQUIP. 8 6.000 6.000 0.000 1.125 1.125 STORAGE EQUIP. 12 0.000 0.000 0.000 0.000 CONVEYORS 12 20,000 20,000 0.000 2.935 2.935 SCREENS 12 0.000 0.000 0.000 0.000 SILOS 12 25.000 25.000 0.000 3.669 3.669 BALE SIEAKERS 12 0.000 0.000 0.000 0.000 ELECTRICAL 12 13.000 13.000 0.000 1.908 1.908 TRANSFOiERAIER. 8 7.000 7.000 0.000 1.312 1,312 BAGGING STATIONS 12 2.000 2.000 0.000 0.294 0.294 WRKSHOP EQUIP. 12 12.400 12.400 0.000 1.820 1.820 OTHERS 12 2.500 2.500 0.000 0.367 0.367 MISC. 12 0.000 0.000 0.000 0.000 SUB-TOTAL 0.000 259.900 259.900 0.000 36.043 36.043 C. SPARES AT DELIVERY 10.0% 14 0.000 25.990 25.990 0.000 3.554 3.554 D. TRANSPORT & DELIV. FREIGHT 4.$ 14 0.000 11.436 11.436 0.000 1.564 1.54 INSURANCE 1.0 14 0.000 2.859 2.859 0,000 0.391 0.391 SITE 01LIVERY 14 1.800 7.300 9.100 0.246 0.998 1.244 SUB-TOTAL (CIF) 1.800 21.595 23.395 0.246 2.953 3.199 E. ENGGO/INSTALL. ENGGPTClilEMENT 5.0$ 20 12.995 12.995 0.000 1.526 1.526 TRAINING 5.0 20 12.995 12.995 0.000 1.526 1.52i INSTALLATION* 20 7.617 30.468 38.085 0.895 3.579 4.473 SUB-TOTAL 7.617 56.458 64.075 0.895 6.632 7.526 CAPITAL COSTS 86,817 383.043 469.860 10.232 51.425 61.658 CONTINGENCY 10.0% 8,682 38.304 46.986 1.023 5.143 6.166 TOTAL CAP. COSTS 95.499 421.347 516.845 11.255 56058 67.823 -3- I I. OPERATING COSTS ARII 28*000 28.000 28000 0.000 28,000 UNSKILLED 7.700 7700 7.700 0.000 7.700 B. POWER ELECTRICITY (I 18.900 18.900 18.900 0.000 18.900 DIESEL (2) 0.000 0.000 0.000 0.000 0.000 C. OPERATION & MAINT. FUEL (3) 0.000 0.000 0.000 0.000 0.000 LUBE 01L 10.0% 0.000 0.000 0.000 0.000 0.000 0.000 SPARE PARTS 10.0% 0.000 25.990 25,990 0.000 25.990 25.990 SERVICES 1.0 2.599 2.599 2.599 0.000 2.599 D. BUILDING MAINT. MATERIALS 3.09 2.895 2.895 2.895 0.000 2.895 E. CONSUM8LES BAGS 20.A00 20.600 20.600 0.000 20,00 OTHER 0.000 0.000 0.000 OPERATING COSTS 80.694 25.990 106,684 80.694 25.900 106.684 CONTINGENCY 10.0% 8.069 2.599 10.668 8.069 2.599 10.668 TOTAL OPER. COSTS 88,763 28.589 117.352 88.763 28.589 117.352 FINANCIAL COST ECONOMIC COST CAPITAL CHARGES/YR 67.823 86.491 OPERATING COSTS/YR 117,352 122.552 FACTORY COST/YR 185.176 209.043 TRANSPORTATION COST/YR 173.300 100.880 TOTAL CHARGES/YR 358.476 309.923 OELIVERED FACTORY DELIVERED FACTORY COST/TON ($) 71.695 37.035 61.985 41.809 COST/4OKS BAG (S) 2.868 1.481 2.479 1.672 COST/UNIT ENERGY (3/0J) 3.630 1.875 3.138 2.117 INSTALLATION LOCAL 3,0% FOREIGN 12.0% (1) ELECTRICITY(KN-H/T) 60.000 (2) POWER-0IESEL(L/rON) (3) FUEL-DIESEL(L/TON) -4- FOOTNOTES TABLE Al 2 IESI0tEs COFFEE HUiSK-DILLA -/ Construction cost components for coffee husks: Plant 68,478 Vorkshop 1.268 Store 2.536 Bagtore 5.918 Office 2,029 Briquette store 16,232 Total buldings 96,461 Detailed discussion In Chapter 3. C/ Labor cost components for coffee husks: 1 Plant manager 7,246 2 Shift supervisors 8,696 4 Plant operators 5,797 1 Mechanic/welder 1,449 1 Bench mechanic 1,449 1 Electrician 1,449 1 Storekeeper/clerk 1,664 12 Labourers 5,217 2 Nightguards 670 Seasonal labour 1750 1,691 mandays/yr 35,747 -5- Table A.3: RESIDUEs COFFEE PULP-OILLA CAPACI Y: 1000.000 TONS ENERGY: 19.320 4/JAK ALL FIGUES IN '000' U.S. DOLLARS CAP. & OPER. COSTS ANNUALIZED COST ITEMS LIFE(YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL l. CAPITAL COSTS A. CONSTiCTION SITE PREPARATION 20 1.700 1.700 0.200 0.000 0.200 BUILDINGS 20 9.900 9.900 1.163 0.000 1.163 HOUSING 20 0.000 0.000 0.000 0.000 SUB-TOTAL 11.600 0.000 11.600 1.363 0.000 1.363 B. EQUIPMENT PISTON BRIQ. 15 0.000 0.000 0.000 0.000 SCREW BRIQ. 15 0.000 0.000 0.000 0.000 COLLECTION EQUIP. 8 26.800 17.900 44.700 5.023 3.355 8.379 STORAGE EQUIP. 12 0.000 0.000 0.000 0.000 CONVEYORS 12 0.000 0.000 0.000 0.000 SCREENS 12 0.000 0.000 0.000 0.000 SILOS 12 0.000 0.000 0.OO 0.000 SALE GREAKERS 12 0.000 0.000 0.000 0.000 EUSCTRICAL 12 0.000 0.000 0.000 0.000 ' ' SFOiER ENER. 8 0.000 0.000 0.000 0.000 BAGGING STATIONS 12 0.000 0.000 0.000 0.000 VOR(SHOP EQUIP. 12 0.000 0.000 0.000 0.000 OTHERS 12 21.100 21.100 0.000 3.097 3.097 MISC. 12 0.000 0.000 0.000 0.000 SUB-TOTAL 26.800 39,000 65.800 5.023 6.452 11.47S C.SPARES AT DELIVERY 10.0% 9 2.680 3.900 6.580 0.456 0.664 1.121 D. TRANSPORT & DELIV. FREIGHT 4.0 9 I.179 1.716 2.695 0.201 0,292 0.493 INSURANCE 1.0% 9 0.295 0.429 0.724 0.050 0.073 0.123 SITE DELIVERY 9 0.100 0.400 0.500 0.017 0.068 0.085 SUB-TOTAL (CIF) 1.574 2.545 4.119 0.268 0.433 0.701 E. ENGG./INSTALL. ENGG./PII0CUREMENT 5.0% 20 3.290 3.290 0.000 0.386 0.386 TRAINING 5.00 20 3.290 3.290 0.000 0.386 0.386 INSTALLATION 20 0.633 2.532 3.165 0.074 0.297 0.372 SUB-TOTAL 0.633 9.112 9.745 0.074 1.070 1.145 CAPITAL COSTS 43.287 54.557 97.844 7.185 8.620 15.805 CONTINGENCY 10.0% 4.329 5.456 9*784 0.718 0.862 1.580 TOTAL CAP. COSTS 47.616 60.013 107.626 7.903 9.482 17.385 -6- II OPERATING COSTS A. LABOR SK I LLED 0.500 0.500 0.500 0.000 0.500 UNSK I LLED 3.800 3.800 3.800 0.000 3.800 B. POWER ELECTRICITY (1) 0.000 0.000 0.000 0.000 0.000 DIESEL (2) 0.000 0.000 0.000 0.000 0.000 C. OPERATION & MAINT. FUEL (3) 2.618 2.618 0.000 2.618 2,618 LUGE OIL 10.0 0.262 0.262 0.262 0.000 0.262 SPAlE PARTS 10.0% 2.680 3.900 6.580 2.680 3.900 6.580 SERVICES 1.0% 0.658 0.658 0.658 0.000 0.658 D. BUILDING MAINT. MATERIALS 3,0$ 0.348 0.348 0.148 0.000 0.348 E. CONSUMABLES BAGS 1.000 1,000 1.000 0.000 1.000 OTHER 0.000 0.000 0.000 OPERATING COSTS 8.986 6.78 15.766 8.986 6,78 15.766 CONTINGENCY 10.0% ,899 6,78 1.577 1.187 6.78 1.577 TOTAL OPER. COSTS 9.885 7.458 17.342 9.885 7.458 17.342 FINANCIAL COST ECONOMIC COST CAPITAL CHARGES/YR 17.385 20.514 OPERATING COSTS/YR 17.342 16.845 BRIQUETING COST/YR 23.470 24.510 FACTORY COST/YR 58.198 61.870 TRANSPORTATION COST/YR 34.660 20.176 TOTAL CHARGES/YR 92.858 82.046 DELIVERED FACTORY DELIVERED FACTORY COST/ON (s) 92.858 58.198 82.046 611.870 COST/4OKG BAG (S) 3.714 2.328 3.282 2.475 COSTANIT ENERGY ($/GJ) 4.806 3.012 4.247 3,202 INSTALLATION LOCAL 3.0% FOREIGN 12.0 (1)ELECTRICITY(KW-H/TN) (2)POWER-DIESEL(L/rON) (3)FUEL-DIESEL(L/TON) 7.000 -7- Table Al.4: RESIDUE: COFFEE PARCHMENT-NEW SITE CAPACITY: 5000.000 TONS ENERGY: 19.330 NJ/KG ALL FIGURES IN '000' U.S. DOLLARS CAP. & (PER. COSTS ANNUALIZED COST ITEMS LIFE (YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL , CAPITAL COS1S A. CONSTRUCTION SITE PREPARATION 20 5,900 6900 0.810 0.000 0.8t BUILDINGS 20 39,000 11.400 50.400 4.581 1.339 5.920 HOUSING 20 0.000 0.000 0.000 0.000 SUB-TOTAL 45.900 11.400 57.300 5.391 1.339 6.730 8. EQUIPMENT PISTON BRIQ. 15 86.000 86.000 0.000 11.307 11.307 SCREW BRIQ. 15 63.000 63.000 0.000 8.283 8.283 COLLECTION EQUIP. 8 0.000 0.000 0.000 0.000 STORAGE EQUIP. 12 0.000 0.000 0.000 0.000 CONVEYORS 12 8.300 8.300 0.000 1,218 1.218 SCREENS 12 0.000 0.000 0.000 0.000 SILOS 12 25,000 25.000 0.000 3.669 3.669 BALE BREAKERS 12 0.000 0.000 0.000 0.000 ELECTRICAL 12 6.200 6.200 0.000 0.910 0.910 TRANSFOfMER/GENER. 8 0.000 0.000 0.000 0.000 BAGGING STATIONS 12 1.200 1.200 0.000 0.176 0.176 WORKSHOP EQUIP. 12 2.400 2.400 0.000 0.352 0.352 OTHERS 12 2.500 2.500 0.000 0.367 0.367 NI SC. 12 0.000 0.000 0.000 0.000 12 0.000 0.000 0.000 0.000 12 0.000 0.000 0.000 0.000 12 SUB-TOTAL 0.000 194.600 194.600 0.000 26.282 26.282 C. SPARES AT DELIVERY 10.0s 14 0.000 19.460 19.460 0.000 2.616 2.616 0. TRANSPORT & DELIV. FREIGHT 4.0% 14 0.000 8.562 8.562 0.000 1.151 1.151 INSURANCE 1.0% 14 0.000 2.141 2.141 0.000 0.288 0.288 SITE DELIVERY 14 1,200 4.800 6.000 0.161 0 45 0.806 SUB-TOTAL (CIF) 1.200 15.503 16.703 0.161 2.084 2.245 E. ENGG./NSTALL. ENGG./PROCUREMENT 5.0% 20 9.730 9.730 0.000 1,143 1.143 TRAINING 5.0% 20 9.730 9.730 0.000 1.143 1.143 INSTALLATION*** 20 5.838 23.352 29.190 0.686 2.743 3.429 SUB-TOTAL 5.838 42.812 48.650 0.686 5.029 5.714 CAPITAL COSTS 52.938 283.775 336.713 6.238 37.349 43.587 CONTINGENCY 10.0% 5.294 28.378 33.671 0.624 3.735 4.359 TOTAL CAP, COSTS 58,232 312.153 370.384 6.862 41.084 47.946 -8- I1. OPERATING COSTS A. LAOR SK I LLED 28.000 26000 28.000 0.000 28.000 UNSK I LLED 7.700 7.700 7.700 0.000 7.700 0. POWER ELECTRICITY (1) 18.900 18.900 18.900 0.000 8.900 DIESEL (2) 0.000 0.000 0.000 0.000 0.000 C. OPERATION & MAINT. FUEL (3) 0.000 0.000 0.000 0.000 0.000 LUBE 01L 10.0$ 0.000 0.000 0.000 0.000 0.000 0.000 SPARE PARTS 10.0$ 0.000 19.460 19.460 0.000 19,460 19.460 SERVICES 1.0% 1.946 1,946 1.946 0.10 1.946 D. BUILDING MAINT. MATERIALS 3.0 1.719 1.719 1.719 0.000 1.719 E. CONSUMABLES BAGS 20.600 20.600 20.400 0.000 20.600 OTHER 0.000 0.000 0.000 OPERATING COSTS 76.865 19.460 98.325 78.865 19.460 98.325 CONTINGENCY 10.0% 7.887 1.946 9.833 7.887 1.946 9.833 TOTAL OPER. COSTS 86.752 21.406 108.156 86.752 21.406 108.158 FINANCIAL COST ECONOMIC COST CAP I TAL CHAGES/YR 47.946 61.504 OPERATING COSTS/YR 108.158 110.986 BRlQUETTING COST/YR FACTORY COST/YR 156.104 172.490 TRANSPORTATION COST/YR 24,000 11.250 TOTAL CHARGEl/YR 180.104 183.740 OELIVERED FACTORY 0ELIVERED FACTORY COST/TON (s) 3.021 31.221 36.748 34.498 COST/40KS 8A ($) 1.441 1.249 1.470 1.380 COSTANIT ENERGY ($/$J) 1.863 1.615 1.901 1.785 ***INSTALLATION LOCAL 3.0% FOREIGN 12.0% (1) ELECTRICITY(KW-H/) 60.000 (2) POWER-DIESEL(L/TON) (3) FUEL-DIESEL(L/ON) . 9 - Table Ao5: RESDUEt COFFEE PACIENT4ERCATO CAPACITY: 2500.000 TONS ENERGY: 19.330 NJ/KG ALL FIGURES IN *000 U.S. DOLLARS CAP, & OPER. COSTS ANNUALIZED COST ITEMS LIFE (YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL I. CAPITAL COSTS A. CONSTRUCTION SITE PREPARATION 20 0.600 0.600 0.070 0.000 0.070 UILDINGS 20 3.400 3.400 0.399 0.000 0.399 HOUS I NG 20 0.000 0.000 0.000 0.000 SUB-TOTAL 4.000 4.000 0.470 0.000 0.470 B. EQilPIENT PISTON BRIQ. 1s 86.000 86.000 0.000 11.307 11.307 SCREW BRIQ. 15 63.000 63.000 0.000 8.283 8.283 COLLECTION EQUIP. 8 0.000 0.000 0.000 0.000 STORAGE EQUIP. 12 0.000 0.000 0.000 0.000 CONVEYORS 12 8.300 8.300 0.000 1.218 1.218 SCREENS 12 0.000 0,000 0.000 0.000 SILOS 12 25.000 25.000 0.000 3.669 3.669 BALE BREAKERS 12 0.000 0.000 0.000 0.000 ELECTRICAL 12 6.200 6.200 0.000 0.910 0.910 TRANSFOMER/ENER. 8 0.000 0.000 0.000 0.000 BAGGING STATIONS 12 1.200 1.200 0.000 0.176 0.176 WORKSHOP EQUIP. 12 2.400 2.400 0.000 0.352 0.352 OTHERS 12 2.500 2.500 0.000 0.367 0.367 ISC. 12 0.000 0.000 0.000 0.000 SUB-TOTAL 0.000 194.600 194.600 0.000 26.282 26.282 C. SPARES AT DELIVERY 10.0% 14 0.000 19460 19.460 0.000 2.616 2.616 0. TRANSPORT & DELIV. FREIGHT 4.0% 14 0.000 8.562 8.562 0.000 1.151 1.151 INSURANCE 10% 14 0.000 2.141 2.141 0.000 0.288 0.288 SITE DELIVERY 14 1.200 4.800 6.000 0.161 0.645 0.806 SUB-OTAL (CIF) 1.200 15.503 16.703 0.161 2.084 2.245 E. ENGG./INSTALL. ENGG./PROCUREMENT 5.0$ 20 9.730 9.730 0.000 1.143 1.143 TRAINING 5.0% 20 9.730 9.730 0.000 1.143 1.143 INSTALLATION"* 20 5.838 23.352 29.190 0.686 2.743 3.429 SUB-TOTAL 5.838 42.812 48.650 0.686 5.029 5.714 CAPITAL COSTS 11.038 272.375 283.413 1.317 36.010 37.327 CONTINGENCY 10.0$ 1.104 27.238 28.341 0.132 3.601 3.733 TOTAL CAP. COSTS 12.142 299.613 311.754 1.449 39.611 41.059 - 10 - II. OPERATING COSTS A. LABOR SKI LLED 14.000 14.000 14.000 0.000 14.000 UNSK I LLED 3.900 3.900 3.900 0.000 3.900 0. POWER ELECTRICITY (1) 9.450 9.450 9,450 0.000 9.450 DIESEL (2) 0.000 0.000 0.000 0.000 0.000 C. OPERATION & MAINT. FUEL (3) 0.000 0.000 0.000 0.000 0.000 0.000 LUSE OIL 10.0s 0.000 0.000 0.000 0.000 0.000 0.000 SPARE PARTS 1.0% 0.000 9.730 9.730 0.000 9.730 9.730 SERVICES 1.0 0.973 0.973 0.973 0.000 0.973 D. BUILDINa MAINT. MATERIALS 3.0% 0.120 0.120 0.120 0.000 0.120 E. CONSUMABLES BAGS 10.300 10.300 10.300 0.000 10.300 OTHER 0.000 0.000 0.000 OPERATING COSTS 38.693 9.730 48.623 38.693 9.730 48.623 CONTINGENCY 10.0% 3.869 0.973 4.862 3.859 0.973 4.842 TOTAL OPER. COSTS 42.562 10.703 53.265 42.562 10.703 53.265 FINANCIAL COST ECONOMIC COST CAPITAL CHARGES/YR 41.059 54.131 OPERATING qost/yR 53.265 54.680 FACTORY COST/YR 94.325 108.811 TRANSPORTATION COST/YR 12.000 5.625 TOTAL CHARGqS/YR 106.325 114.436 OELIVERED FACTORY DELIVERED FACTORY COST/TON (5) 42.530 37.730 45.774 43.524 COST/4OKG BAG ($) 1.701 1.509 1.831 1.741 COSTAINIT ENE$BY (S/J) 2.200 1.952 2.368 2252 ***INSTALLATlq% LOCAL 3.0S FORE IGN 12.0% (1) ELECTRICITY(KW-H/T) 60.000 (2) POWER-DIESEL(L/TON) (3) FUEL-DIESEL(L/TON) - 11 - Table AI,6: RESJOUEt COTON STALKS-AWASH CAPACITY: 5000.000 TONS ENERGY: 17.800 NJ/AG ALL FIGURES IN 1000* U.S. DCLLARS CAP. & OPER. COSTS ANNUALIZED COST ITEMS LIFE (YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL 1. CAPITAL COSTS A. CONSTRUCTION4- SITE PREPARATION 20 10.000 10.000 1.175 0.000 1.175 BUILDINGS 20 49.600 12.400 62.000 5.826 1.456 7.282 HOUSING 20 112.500 28.100 140.600 13.214 3.301 16.515 SUB-TOTAL 172.100 40.500 212.600 20.215 4.757 24.972 8. EQUIPMENki PISTON BRIQ. 15 172.000 172.000 0.000 22.613 22.613 SCREW BRIQ. 15 0.o00 0,000 0.000 0.000 COLLECTION EQUIP. 8 204.800 204.800 0.000 38.389 38.389 STORAGE EQUIP. 12 17.000 17.000 0.000 2.495 2.495 CONVEYORS 12 23.200 23.200 0.000 3.405 3.405 SCREENS 12 3,000 3.000 0.000 0.440 0.440 SILOS 12 20,000 20.000 0.000 2.935 2.935 BALE BREAKERS 12 21.000 21.000 0.000 3.082 3.082 ELECTRICAL 12 12.200 12.200 0.000 1.791 1.791 TRANSFORMER/GENER, 8 106.300 106.300 0.000 19.925 19.925 BAGING STATIONS 12 2.400 2.400 0.000 0.352 0.352 wORKSHOP EQUIP. 12 24.200 24.200 0.000 3.552 3.552 OTHERS 12 4.500 4.500 0.000 0.660 0.660 MISC. 12 0.000 0.000 0.000 0.000 12 0.000 0.000 0.000 0.000 12 0.000 0.000 0.000 0.000 SUB-TOTAL 0.000 610.600 610.600 0.000 99.640 99.640 C.SPARES AT DELIVERY 10.0$ 11 0.000 61.060 61.060 0.000 9.496 9.496 D. TRANSPORT & OELIV. FREIGHT 4.0% 11 0.000 26.866 26.866 0.000 4.178 4.178 INSURANCE 1.0s 11 0.000 6.717 6.717 0.000 1.045 1.045 SITE DELIVERY 11 1.000 4.100 5.100 0.156 0.638 0.793 SUB-TOTAL (CIF) 1.000 37.683 38.683 0.156 5.860 6.016 E. ENGG./INSTALL. ENG./PROCUREMENT 5.0 20 30.530 30.530 0.000 3.586 3.56 TRAINING 5.0% 20 30.530 30.530 0.000 3.566 3.586 INSTALLATION" 20 12.174 48.696 60.870 1.430 5.720 7.150 SUB-TOTAL 12.174 109.756 121.930 1.430 12.892 14.322 CAPITAL COSTS 185.274 859.599 1044.873 21.800 132.645 154.446 CONTINGENCY 10.0 18.527 85.960 104.487 2.180 13.265 15.445 TOTAL CAP. COSTS 203.801 945,559 1149.360 23.960 145.910 189.890 - 12 - II. OPERATING COSTS A. LABOR S' SKI LLED 40.400 40.400 40.400 0.000 40.400 UNSKILLED 13.900 13.900 13,900 0.000 13.900 B. POWER ELECTRICITY (1) 0.000 0.000 0.000 0.000 0.000 DIESEL (2) 54.604 54.604 0.000 54.604 94.04 C. OPERATION & MAIN. FUEL (3) d/ 8.228 8.228 0.000 8.228 8.228 LUBE OIL 10.0% 6.283 6.283 6.283 0.000 6.283 SPAlE PARTS 10.0$ 0.000 51.060 61.060 0.000 61.060 61.060 SERVICES 1.0% 6,106 6.106 6.106 0.000 6.106 D. BUILDING 1AINT. MATERIALS 3.0 6.378 6.378 6.378 0.000 6.378 E. CONSUMABLES BAGS 20.600 20.600 20.600 0.000 20.600 OTHER 1.000 1.000 1.000 0.000 1.000 OPERATING COSTS 88.384 130.175 218.559 88.384 130.175 218.559 CONTINGENCY 10.0% 8.838 13.018 21.856 8.838 13.018 21.856 TOTAL OPER. COSTS 97.222 143.193 240,415 97.222 143.193 240.415 FINANCIAL COST ECONOMIC COST CAPITAL CIAtES/YR 169.890 218.040 OPERATING COSTS/YR 240.415 259.185 FACTORY COST/WR 410.305 477.226 TRANSPORTATION COST/YR 159.400 88.650 TOTAL CHARGES/YR 569.705 565.876 DELIVERED FACTORY DELIVERED FACTORY COST/TON ($) 113.941 82.061 113.175 95.445 COST/40K$ BAO (S) 4.558 3.282 4.527 3.818 COSTAJNIT ENERGY (SGJ) 6,401 4.610 6.358 5.362 *INSTALLATION LOCAL 3,0% FOREIGN 12,0$ (1) ELECTRICITY(KW-H/TON) 70.00 (2) POWER-DIESEL(L/rON) 29.200 (3) FUEL-DIESEL(L/TON)d/ 4.400 - 13 - FOOTNOTES TABLE A1.6 IES0tE: CTTON STALKS-AWASH Construction cost components for cotton res-dues: Site preparation 10,000 Buildings Plant 32,609 Power house 3,804 Workshop 2,536 Parts store 3,804 Bagstore 4,227 Briquette store 9,275 Office 2,029 Parking shed 3,092 Equipment foundations 604 61,978 Housing requirements Plant manager 8,696 18 Skilled labourers 69,565 32 Parm, Labourers 61,836 Seasonal (drivers) 560 140,677 3=m8383= Detailed discussion in Chapter 4. Labor cost components for cotton residues Col lection and Storage Personnel 7 Tractor Drivers 1,692 1 Headman 145 3 Labourers 217 2,054 Briguetting Plant Personnel 1 Plant Manager 7,246 2 Shift supervisors 1 8,696 4 Plant operators 5,797 2 Powerplant operators 2,319 4 Tractor drIvrs 4,831 - 14 - 1 Mchanic/welder 1,449 1 Electrician 1,449 1 Machine operator 1,449 1 Tractor mechanic 1,594 1 Storekeeper/clerk 1,884 1 Clerk 1,884 27 Permanent Labourers 11,739 3 Labourers (10 months) 1,087 2 Nightguards 870 52,294 8888888 d/ Fuel Requirements for Collection of Cotton Residues Hours LAR Baling 2,400 6 Hauling 1,527 5 Fuel (L) 22,035 Capacity (TON) 5,000 Fuel-Diesel (L/T) 4,407 15 - Table At.7.: RESIDUE: WHEAT STRAW-DIXIS CAPACITY: 5000.000 TONS ENERGY: 18.050 NJ/KG ALL FIGUMES IN 10001 U.S. DOLLARS CAP. & OPER. COSTS ANNUALIZED COST ITEMS LIFE(YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL 1, CAPITAL COSTS A. CONSlUCTION 2" SITE PREPARATION 20 10.000 10.000 1.175 0.000 1.175 BUILDINGS 20 62.200 15.400 77.600 7.306 1.809 9.115 HOUSING 20 115.000 28.400 143.400 13.508 3.336 16.844 SUB-TOTAL 187.200 43.800 231.000 21.988 5.145 27.133 B. EAfPMENT PISTON GRIQ. 15 215.000 215.000 0.000 28.267 28.267 SCREW SRIQ. 15 0.000 0.000 0.000 0.000 COLLECTION EQUIP. 8 98.500 98.500 0.000 18.463 18.463 STORAGE EQUIP. 12 9.000 9,000 0.000 1.321 1.321 CONVEYORS 12 23.500 23.500 0.000 3.449 3.449 SCREENS 12 3.000 3.000 0.000 0.440 0.440 SILOS 12 20,000 20.000 0.000 2.935 2.935 SALE SMAKERS 12 40,000 40.000 0.000 5.871 5.871 ELECTRICAL 12 12.200 12.200 0.000 1,791 1.791 TRANSFONERiAENR. 8 106.300 106.300 0.000 19.925 19.925 BAGGING STATIONS 12 2.400 2.400 0.000 0.352 0.352 WOIKSHOP EQUIP. 12 24.200 24.200 0.000 3.552 3.552 OTHERS 12 54coo 5.000 0.000 0.734 0.734 MISC. 12 0.000 0.000 0.000 0.000 SUB-TOTAL 0.000 559.100 559.100 0.000 87.100 87.100 C. SPARES AT DELIVERY 10.0s 12 0.000 55.910 55.910 0.000 8.323 8.323 D. TRANSPORT & DELIV. FREIGHT 4.0% 12 0.000 24.600 24.600 0.000 3.662 3.662 INSURANCE 1.0$ 12 0.000 6.150 6.150 0.000 0.916 0.916 SITE DELIVERY 12 1.700 6.900 8.600 0.253 1.027 1.280 SUB-TOTAL (CIF) 1.700 37.651 39.351 0.253 5.605 5.858 E. ENGG./INSTALL. ENG.PROCIEENl 5.0S. 20 27.955 27.955 0.000 3.284 3.284 TRAINING 5.0% 20 27.955 27.955 0.000 3.284 3.284 INSTALLATIOP" 20 13.818 55.272 69,090 1.623 6.492 8.115 SUB-TOTAL 13.818 111.182 125.000 1.623 13,059 14.682 CAPITAL COSTS 202.718 807.643 1010.361 23.865 119.231 143.096 CONTINGENCY 10.0% 20.272 80.764 101.036 2.386 11.923 14.310 - 16 - TOTAL CAP. COSTS 222.990 888.407 1111.397 26.231 131.154 157.405 I I, OPERATING COSTS A. LAOR 11 SKILLED 33.400 33.400 33.400 0.000 33.400 UNSKILLED 7.200 7.200 7.200 0.000 7.200 B. POWER ELECTRICITY(1) 0.000 0.000 0.000 0.000 0.000 DIESEL(2) 66.198 66.198 0.000 66.198 66.198 C. OPERATION & MAINT. FUEL(3) 6.919 8.919 0.000 6.919 6.919 LUBE OIL 10.0% 7.312 7.312 0.000 7,312 7.312 SPARE PARTS 10.0% 0.000 35.910 55.910 0.000 55.910 55.910 SERVICES 1.0% 5.59 5.591 5,591 0.000 5.591 D. BUILDING NAINT MATERIALS 3.00 6.930 6.930 6.930 0.000 6.930 E. CONSUABLES BAGS 20.600 20.600 20.600 0.000 20.00 OTHER 13.500 13.500 0.000 13.500 OPERATING COSTS 87.221 136.339 210.060 87.221 136.339 223.560 CONTINGENCY 10.0 8.722 13.634 22.356 8.722 13.634 22.356 TOTAL OPER. COSTS 95.943 149.973 245.916 95.943 149.973 245.916 FINANCIAL COST ECONOMIC COST CAPITAL CIMGES/YR 157.405 200.686 OPERATING COST/YR 245.916 267.197 BRIQUETTING COST/YR FACTORY COST/YR 403.321 467.883 TRANSPORTATION COST/YR 170.048 61,400 TOTAL CHAtGES/YR 573.369 529.283 DELIVERED FACTORY DELIVERED FACTORY COST/TON(S) 114.674 80.664 105.857 93.577 COST/40NG M(S) 4.587 3.227 4.234 3.743 COST/UNIT ENERGY(SAJ) 6.353 4.469 5.865 5.184 *"INSTALLATION LOCAL 3.00 FOREIGN 12.0% 0 )ELECTRICITY0f-I/N) (2)POlER-DIESEL(L/ON) 35.400 (3)FUEL-DIESEL(L/TON) 3.700 - 17 - FOOTNOTES Table At.? IESI0UE: *EAT STRAW-DIXIS Construction cost components for wheat straw: Site preparation 10,000 w8aata 8ulidings Plant 32,609 Reception 10,870 Workshop 2,536 Powerhouse 3,604 Briquette store 9,275 Office 2,029 Bagstore 4,227 Parts store 3,804 Parking shed 7,729 Foundation equipment 725 Total buildings 7,608 -3an33=3 Housing requirements Plant manager 8,696 16 Skilled labourers 61,836 32 Unskilled labourers 61,836 Seasonal labour 11,014 Total housing requirements 143,382 Detailed discussion In Chapter 5. Labor cost components for wheat straw: Residue collection and storage personnel 3 Baler oprators 1,090 2 Tractor drivers 725 40 Labourers 3,785 I headman 435 6,035 "##aa- Briquettind plant personnel 1 Plant manager 7,246 2 Shift supervisors 8,696 4 Plant operators 5,797 - 18 - 2 Drivers 2,174 1 Welder (mechanic) 1,449 1 Machine operator 1,449 1 Electrician 1,449 1 Tractor mechanic 1,594 1 Storekeeper/clerk 1,884 6 Labourers 1,957 2 Nightguards 870 34,565 RaCsas Fuel requirements for collection of wheat straw residues: Hours LAHR Baling 1,000 6 Hauling 1,500 5 Fuel (L) 18,300 Capacity (TON) 5,000 Fuel-Diesel (L/T) 3,660 - 19 - Table A1.8: RESIDUE: CORN STALKS AND STOVER CAPACITY: 5000.000 TONS . ENERGY: 18.650 NJ/KS ALL FIGURES IN '000' U.S. DOLLARS CAP. & OPER. COSTS ANNUALIZED COST ITEMS LIFE (YRS) LOCAL FOREIGN TOTAL LOCAL FOREIGN TOTAL 1. CAPITAL COSTS A, CONSTRUCTION a SITE PREPARATION 20 10.000 10.000 1.175 0.000 1.175 BUILDINGS 20 65.800 16.400 82.200 7.729 1.926 9.655 HOUSING 20 177.700 44.400 222.100 20.873 5.215 26.088 SUB-TOTAL 253.500 60,800 314.300 29.776 7.142 36.918 B. EQUIPMEhT PISTON BRIQ. 15 206.400 206.400 0.000 27.136 27.136 SCREW BRQ. 15 0.000 0.000 0.000 0.000 COLLECTION EQUIP. 8 238.100 238.100 0.000 44.630 44.630 STORAGE EQUIP, 12 37.200 37.200 0.000 5.460 5.480 CONVEYORS 12 23.500 23.500 0.000 3.449 3.449 SCREENS 12 3.000 3.000 0.000 0.440 0.440 SILOS 12 20.000 20.000 0.000 2.935 2.935 BALE BREAKERS 12 40.000 40.000 0.000 5.871 5.871 ELECTRICAL 12 12.200 12.200 0.000 1.791 1.791 TRANSFORERME ENER. 8 127.500 127.500 0.000 23.899 23.899 BAGGING STATIONS 12 2.400 2.400 0.000 0.352 0.352 WORKSHOP EQUIP. 12 24.200 24.200 0.000 3.552 3.552 OTHERS 12 5.000 5.000 0.000 0.734 0.734 mISC. 12 0.000 0.000 0.000 0.000 SUB-TOTAL 0.000 739.500 739.500 0.000 120.249 120.249 C.SPARES AT DELIVERY 10.0s 11 0.000 73.950 73.950 0.000 11.469 11.469 D. TRANSPORT & CELIV. FREIGHT 4.0S 11 0.000 32,538 32.538 0.000 5.046 5.046 INSURANCE 1.0% 11 0.000 8.135 8.135 0.000 1.262 1.262 SITE DELIVERY 11 2*700 10.800 13.500 0.419 1.675 2.094 SUB-TOTAL (CIF) 2.700 51.473 54.173 0.419 7.983 8.402 E, ENGG./INSTALL. ENG9,APRCUREMENT 5.0% 20 36.975 36.975 0.000 4.343 4.343 TRAINING 5.0$ 20 36.975 36.975 0.000 4.343 4.343 INSTALLATION* 20 15.042 60.168 75.210 1.767 7.067 8.834 SUB-TOTAL 15.042 134.118 149.160 1.767 15.753 17.520 CAPITAL COSTS 271.242 1059.841 1331.083 31.962 162.595 194.557 CONTINGENCY 10.0% 27.124 105.964 133.108 3.196 16.20 19.456 TOTAL CAP. COSTS 298.366 1165.825 1464.191 35.158 178.655 214.013 - 20 - I I. OPERATING CSTS A. LABOR 2 SKI LLED 40.800 40.800 40.800 0.000 40.800 UNSKILLED 42.800 42.800 42.800 0.000 42.800 B. POWER ELECTRICITY(1) 0.000 0.000 0.000 0.000 0.000 DIESEL(2) 70.125 70.125 70.125 0.000 70.125 C. OPERATION & MAINT. FUEL (3l 11.669 11.669 0.000 11.669 11.669 LUSE OIL 10,0 8,179 - 8.179 8.179 0.000 8,179 SPARE PARTS 10.0% 0.000 73,950 73.950 0.000 73.950 73.950 SERVICES 1.0% 7.395 7.395 7.395 0.000 7.395 D. BUILDING MAINT. MATERIALS 3.0% 9.429 9.429 9.429 0.000 9.429 E. CONSUMABLES BAGS 20.600 20.400 20.600 0.000 20.600 OTHER 13.500 13.500 0.000 13.500 OPERATING COSTS 134.526 163.923 298.447 134.52 163.923 298.447 CONTINGENCY 10.0% 13.452 16,392 29.845 13.452 16.392 29.845 TOTAL OPER., COSTS 147.976 160,315 328.292 147.976 180.315 328.292 FINANCIAL COST ECONOMIC COST CAPITAL CHARGES/YR 214.013 273,035 OPERATING COSTS/YR 328.292 337.129 FACTORY COST/YR 542.304 610.163 TRANSPORTATION COST/YR 159,400 113.110 TOTAL CHARGES/YR 701,704 723.273 DELIVERED FACTORY DELIVERED FACTORY COST/TON (S) 140.341 108.461 144.655 122.033 COST/40KS BAD (S) 5,614 4.338 5.786 4.661 COST/UNIT ENERGY (S/GJ) 7.525 5.816 7.756 6.543 mINSTALLATION LOCAL 3.0% FOREIGN 12.0$ (1) ELECTRICITY(KWI-H/ON) (2) POWER-DIESEL(L/TON) 37.500 (3) FUEL-DIESEL(L/TON) 6.240 - 21 - FOOTNOTES Table At.8 IESIOUE: Ot STAKS AND STOVER Construction cost componants for corn residues: Site Preparation 10,000 WWWWa@ua Buildings Plant 32,609 Reception 14,493 Power-house 3,804 Gasif ior 3,551 Cobstore 1,268 Workshop 2,174 Parts store 3,804 Briquette Store 9,275 Office 2,029 Bagstore 4,227 Parking shed 3,865 Equipment foundation 1,087 82,186 Housing requirements Plant manager 8,696 18 Skilled labourers 69,565 38 Permanent labourers 73,430 Seasonal labour 70,435 222,128 3338 Detailed discussion in Chapter 6. Labor Cost components for corn residues: Residue collection and Storage Personnel 240 Labourers 26,087 9 Tractor drivers 3,261 6 Baling labourers 652 2 Headmen 870 30,870 3a3"M. Briquetting Plant Personnel 1 Plant manager 7,246 - 22 - 2 Shift supervisors 8,696 4 Plant operators 3,797 2 Power plant operators 2,319 2 Gasifier operators 2,319 2 Tractor drivers 2,174 1 MechanIc/welder 1,449 1 Machine operator 1,449 1 Electrician 1,449 1 Tractor mechanic 1,594 1 Store-keeper/clerk 1,884 1 Clerk 1,684 32 Labourers 11,643 2 Nightguards 870 32,730 wuggaWa Fuel Requirements for Collection of Corn Residues: Hours LAHR Chopping 3,350 6 Transport 1,912 5 Cobb Trans 310 5 Fuel (L) 31,210 Capacity (TON) 5,000 Fuel-Diesel (L/T) 6,242 - 23 - Table A1.9 SENSITIVITY ANALYSIS 888888888888uu888888 (1) PRODUCTION CAPACITY(TONS/YR) VS. DELIVERED COST(S/ON) CAPACITY 1000 2000 3000 4000 5000 6000 7000 8000 COFFEE DILLA-4USK 153.660 102.432 85.356 76.818 71.695 68.280 65,841 64.011 COFFEE DILLA-PULP 120.564 92.410 83.026 78.333 75.518 73.641 72.300 71.295 COFFEE PARCH.-NEW SITE 91.502 56.828 45.268 39.488 36.021 33.709 32.058 30.819 COFFEE PARCHo.-MERCATO 73.38? 47.706 39.079 34,766 32.177 30.452 29,220 28.295 COTTON STALKS-AWASH 303.586 185.058 145.549 125.794 113.941 106.039 100.395 96.162 WHEAT STRAW-DIXIS 289.799 180.346 143.861 125.619 114.674 107.377 102.165 98.256 CORN STALKS AND STOVER 376.627 228,948 - 179.722 155.109 140.341 130.496 123.463 118.189 (2) DISCOUNT RATE(M) VS. DELIVERED COST($/TON) DI SCOUNT RATE 6.00% 8.00% 10.00% 12.00% 14.00% 16.00% 18.00% 20.00 COFFEE DILLA-HUSK 68.713 70.163 71.695 73.301 74.973 76.701 78.479 80.300 COFFEE DI LLA-PULP 89.897 91.345 92.858 94.431 96.060 97.737 99.459 101.222 COFFEE PAltCH.-NEW SITE 33.880 34.920 36,021 37.175 38.376 39.619 40.897 42.207 :COFFEE PARCH.-ERCATO 38.958 40.695 42.530 44.453 46.454 48.525 50.657 52.841 COTTON STALKS-AWASH 107.461 110.621 113.941 117.407 121.002 124.712 128.524 132.425 WHEAT STRAW-DIXIS 108.348 111.429 114.674 118.066 121.589 125.228 128.967 132.794 CORN STALKS AM STOVER 132,058 136.095 140.341 144.774 149.374 154.122 159.000 163.992 (3) SERVICE LIFE-RIQUETTORS(YEARS) VS. DELIVERED COST(/TON) SERVICE LIFE 6 8 10 12 14 16 18 20 COFFEE DILLA-HUSK 75.989 74.194 73.113 72.397 71.893 71.524 71.245 71.030 COFFEE DI LLA-PULP 92.858 92.858 92,858 92.858 92.858 92.858 92.858 92.858 COFFEE PARCH.-NEW SITE 39,740 38.174 37.237 36,620 36.189 35.876 35.640 35.460 COFFEE PARCH.-4ERCATO 49.968 46.836 44.962 43.729 42.867 42.240 41.769 41.408 COTTON STALKS-AWASH 118.265 116.501 115,420 114.686 114.155 113.753 113.439 113.188 WHEAT STRAt-DIXIS 120,052 117.841 116,493 115.585 114.934 114,447 114,071 113.775 CORN STALKS AND STOVER 145.562 143.438 142,133 141.243 140.601 140.113 139.730 139.424 (4) POWER REQUIREMENTS(K-H/TON) VS. DELIVERED COST($/TON) POWER -60.00% -40,00% -20.00% 0.00% 20.00% 40.00% 60.00% 80.00% COFFEE DILLA-MUSK 69.200 70*032 70,864 71.695 72.527 73.358 74.190 75.022 COFFEE DILA-PULP 92.858 92.858 92,858 92.858 92.858 92.858 92.858 92.858 COFFEE PARCH.-NEW SITE 33.526 34.358 35.189 36,021 36.852 37.684 38.516 39.347 COFFEE PARCH,-MERCATO 40,035 40.867 41.698 42.530 43.361 44.193 45.023 45.856 COTTON STALKS-AWASH 106.013 108.655 11.298 113.941 116.584 119.227 121.870 124.512 WHEAT STRAW-DIXIS 105.062 108.266 111.470 114.674 117.878 121.082 124.286 127.490 CORN STALKS AND STOVER 130.159 133.553 136.947 140.341 143.735 147.129 150.523 153.917 DISCOUNT RATE ANALYSIS 1'70 140- 120 110 05 Go- eo - 40- 20- 8.00% CR .C0 1 0.M 12.003 14.009 18.001 1 8.0= 20.0= 115CUNT MtAM M 0£A 4 a c då 0 x e Tp PRODUCTION CAPACITY ANALYSIS a00.00 .100.00 soo.o 30.00 1000 2000 3ED 70M = 0caArrr f roaY) DA 4U * C AD XE YFF m . O 3 I-r o rr >Cw C O 0 (.- O4.. i, z -27- Annex 2 CMICAL AND PHYSICAL ANALYSIS OF ETHIOPIAN AGRICULTURAL-RESIDUES BRIQUETTING (TNO REPORT) *-28- netherlands organization for division of technology for society applei scientific resarch SUITABILITY TESTS OP BRIQUETTES FROM ETRIOPEAN AGRICULTURAL RESIDUES by by po. box 342 Ir. C.E. Krist-Spit 7M00 AI apeldoorn Ing. G. Wentink address lean van westenenk 501 telex 36895 tnop phone 055 -?733 44 Ref.r. : 85-011883 Filear. : 8725-13801 Date : August 1985 N.P. . Keywords: briquettes, agricultural residues, combustion tests, friability. Revision of report ref.nr. 85-010114 To: World Bank .No part of this report shall be mul* tlpiled andlor published by way of Energy Assessment Division print. photostat cooy, microfilm or otherwise. without To's prior con. Energy Department sent." 1818 N Street N.W. Ifthisreport hasbeen madeaccord- Ing to lnstructions, the rihts and Washington D.C. 20433 obligations of fth principal and TNO are as laid down in the,8tan. U.S.A. dard conditions for research and development Instructions to TNO. 1979". or In the relevant agreement reached between the parties. 01985. TNO. The Hague. - 29 - SUMMARY Within the framework of a feasibility study of briquetting plants for Ethiopia, the World Bank commissioned the Netherlands Organization for Applied Scientific Research, TNO, Division of Technology for Society, Apeldoorn, the Netherlands to test briquettes of five agricultural resi- dues from Ethiopia in order to assess their suitability for domestic and other purposes. The five residues concerned are: corn stover, cotton stalks, wheat stra:, white coffee parchment and black coffee husks. In fact, two different species of black coffe husks could be distinguished, the so-called agglo- merated and non-agglomerated specie. It was attempted to compress all residues by a conical screw extruder. Good briquettes resulted from the corn stover, cotton stalks and white coffee parchment, but the compression of the wheat straw and black coffee husks was unsuccessful. Therefore those materials were compressed by a hydraulic piston press. Because the preprocessing of the materials had taken place in accordance with the specifications imposed by the conical screw extruder the characteristics of the material fed into the hydraulic piston press were not optimal. The quality of the resulting briquettes may not be termed representative for the quality that can be obtained by such a compression process. Moreover, black coffee husks briquettes were produced only from the agglomerated species. The results obtained with the latter briquettes may not be valid for the non-agglomerated species of black coffee husks. The briquettes were submitted to an extensive testprogramme comprising the determination of their composition, the fusion behaviour of the ashes and several physical properties including the friability of the briquettes, the resistance to storage in a humid atmosphere and the bulk densities of raw materials and biiquettes. Finally, combustion tests were carried out in a domestic metal cooking stove. Comparisons were made with combustion results of Eucalyptus. On the basis of the testdata it can be concluded that the three "screw- made" briquettes from cotton stalks, corn stover and white coffee p%rch- ment are most likely to be suitable to serve as fuel for domestic use. The - 30 - results with regard to their resistance to storage in a humid atmosphere and their resistance to mechanical shocks from transport - even after their exposure to a humid atmosphere * were good and the results may be expected to be even better under more favourable atmospheric conditions. The combustion tests rendered results that were comparable to, or even slightly better than those from tests conducted with Eucalyptus. The wheat strav briquettes rendered good results with regard to their combustion. However, the resistance of this particular briquette to mechanical shocks - even in dry condition - must be termed poor. Therefore their suitability for domestic use must be doubted, and further examina- tion of the compression potentials of this material is recommended. The particular agglomerated black coffee husks briquettes that were produced during this project, are of a very poor quality in every respect, although the lignin content of the material is not in any way lower than the content of the other materials. The briquettes may be crumbled by hand, and they did not survive any of the mechanical tests they were submitted to, nor did they outlive their exposure to a humid atmosphere. The combustion tests also rendered poor. results because of the bad ignition qualities of the briquettes and the fact that they disintegrated during the combustion process. Whether the briquettes may be suitable for other than domestic purposes will largely depend on the process under consideration. - 31 1. INTRODUCTION Within the framework of a feasibility study of briquetting plants for Ethiopia, the World Bank comissioned the Netherlands Organi- zation for Applied Scientific Research, TNO, Division of Technology for Society, Apeldoorn, the Netherlands to test briquettes of five agricultural residues from Ethiopia in order to assess their suitabi- lity for domestic and other purposes. The five residues concerned are corn stover, cotton stalks, wheat straw, white coffee parchment and black coffee husks. In fact, two slightly different species of black coffee husks could be distin- guished, the so-called agglomerated and non-agglomerated husks. The raw materials were transported by air from Ethiopia and had to be compressed in Europe. This report describes the compression of the materials (section 2) and presents the results of the testprograme to which the bri- quettes were submitted. The test programme comprised the determination of the composition of the materials (section 3) and the ashes (section 4); the deter- mination of the calorific value (section 3) and combustion tests performed in a domestic one-hole metal stove without chimney (sec- tion 8); the determination of the fusion behaviour of the ashes (section 4); and finally, the determination of several physical pro- perties, namely the basic- and bulk densities of the raw materials and the briquettes (section 5), the resistance to storage in a humid atmosphere (section 6) and the friability of the briquettes (section 7). Conclusions are drawn in section 9 of the report. Various institutes and firms have contributed to the execution of the testprogramme.and will be mentioned in the relevant sections. - 32 - 2. COMPRESSION Before a material can be fed into a press certain specifications con- cerning moisture content and particle size have to be met. The resi- dues were ground and dried by the "Centre de Recherches Agronomiques" (C.R.A.), Gembloux, Belgium. The material was dried to below 5% mois- ture content. The grinding to a particle size between I and 10 am was performed by a hammer mill. The cotton stalks, corn stover and white coffee parchment were com- pressed by a conical screw press of Biomass Development Europe s.a. (B.D.E.), Brussels, Belgium. The briquettes produced have a diameter of 30 mm and vary in length between 5 and 15 cm. Attempts to compress the wheat straw and the black coffee husks with this equipment were unsuccessful, because the pressure build-up was insufficient. The sketch of fig. I shows the working principle of the extruder: First the material is compressed by the conical screw. The screw-head cuts the material and forces it into the die. Owing to the friction the material is heated to above 200 OC, which causes the lignin to fuse and act as a binder. The working pressure largely de- pends oi the friction that is generated in the die. This depends on the die lay-out (number and diameter of the holes) and the die length, in combination with the material properties. The bad compression results with the black coffee husks and the wheat straw cannot be explained by a lower lignin content than the content of the other materials (see section 3); nor by the temperature build- up, which was sufficient to cause the lignin to fuse. Apparently the friction that was generated in the die was insufficient, to build up high enough a pressure. It is the experience of B.D.E. that any wood species may be compres- sed into good quality briquettes with dies consisting of 7 or 8 holes with a 30-mm diameter and lengths varying between 170 and 180 mm. During the compression trials of the black coffee husks and the wheat straw, dies consisting of 7 holes and a 173-mm length and 8 holes and a 180-mm length were used. The proceeding of the compression trials has given rise to the impression that a longer die might have led to better results. However, owing to B.D.E.'s experience quoted above, no longer die was available. -33- MT-TNO Conical screw extruder -13801 Fig. I - 34 - The conical screw press operated at a power of about 45 kW. A rough estimate of the briquette output from the press comes to 500 kg/h for the three materials. The moisture content of the material entering the press should be below 5% and the particle size 1 - 10 mm. The remainder of the black coffee husks and the wheat straw was com- pressed by a hydraulic piston press of lusters b.v., Venlo, the Netherlands. While C.R.A. appeared to have kept part of the wheat straw this quantity was still available for compression at lusters. The quantity of wheat straw that was not used during the compression attempts at*B.D.E. was added to this. As for the black coffee husks it appeared that only the agglomerated species was kept unused at B.D.E. This was sent to lusters. The input condition of both mate- rials was 1-10 mm particle size and about 5% moisture content. The demands concerning the particle size and moisture content of the material to be fed into the hydraulic piston press are less severe than those concerning the conical screw press, namely below 20 mm and 18% respectively. Therefore the particle size of 1-10 mm and the moisture content of 5% were not ideal characteristics and may have influenced the resulting briquette quality. The briquettes produced have a diam^-ter of 50 mm.and vary in length between I and 8 cm. The agglomerated black coffee husks briquettes are of a poor quality because their composition is very loose. The quality of the wheat straw briquettes is slightly better, although still very moderate. Compared to known compression results of wood wastes with the same press the quality of the br.quettes produced cannot be termed representative for this production method. The briquettes were produced by one of Kusters' smaller presses ope- rating at a power of 15 kW. The briquette output amounted to roughly 150 kg/h for both materials. The press operated at a pressure of about 1200 bar. Table I summarizes the overall results of preprocessing and compres- sion. -35- Table 1: Quantities of raw materials and briquettes Raw Quantity Quantity Quantity Quantity Quantity Quantity naterial received left after sent to of briquet- sent to of briquet- by CRA grinding B.D.E. tes pro- Kusters tes pro- and drying duced at duced at B.D.E. KUsters (kg) (kg) (kg) (kg) (kg) (kg) orn stovPr 192 139 (72% 119 96.9 * * otton stalks 118 75.5 (64% 51.5 30.9 - - heat straw 153 145 (95% 106 * 110 72.0 ite coffee 180 168 (93%) 168 51.3 * - archment usks gglomerated 150 100 (67%) 100 - 100 57.4 lack coffee usks The reduction in mass after grinding and drying is caused by loss of moisture and formation of dust. Table 2 shows the moisture content of the raw materials on receipt at C.R.A. Table 2: Initial moisture content of the raw materials as received by C.R.A. raw material moisture content (% on a dry-matter basis) Corn stover 9.7 Cotton stalks 14.4 Wheat straw 9.6 White coffee parchment 4.4 Black coffee husks 12.2 Agglomerated black 12.3 coffee husks "JU It is obvious that the reduction in mass c uot solely be accounted for by the drying process to below 5% moisture content. The major part of the loss is caused by the formation of dust during grinding. Part of this could pot be recovered by the cyclone that was used. However, because C.R.A. does not use industrial equipment, the mass reduction due to drying and grinding, presented in table 1, can- not be considered to be representative of the losses that will occur in practice. . It should be noticed that where this report speaks of black coffee husks briquettes in fact agglomerated black coffee husks briquettes are meant. Because the origine of the agglomerated and non-agglome- rated species of black coffee husks is unknown - while no indications whatsoever accompanied the residues at their arrival in Belgium - it is not clear to what extent the conclusions about the agglomerated husks may be valid for the non-agglomerated husks too. - 37 - 3. COMPOSITION AND CALORIFIC VALUE OF THE BRIQUETTES The gross and net calorific value of the briquettes were determined in accordance with the International Standard ISO 1928-1976. The lignin content was determined by C.R.A. Gembloux and constitutes an average of 3 measurements. The analysis determining the sulphuric lignin uses the Ritter method adapted to an automatical Fibertec (Tecator) apparatus. The standard error S is given in brackets. The species of Eucalyptus wood used for the combustion tests that wore conducted for the sake of comparison is named Eucalyptus Globulus La- bil. This species was long ago imported into Ethiopia and contributed in this way to the development of Addis Abeba into the country's Major city [I]. Table 3 shows the composition and the calorific value of the briquet- tes and the Eucalyptus. Except for the moisture content all data are given on a dry-matter basis. It should be noticed that the moisture content of the briquettes used in the combustion tests was lower than the moisture content shown in table 3. This is caused by the fact that the samples that were analyzed had for some time been exposed to the ambient atmosphere in pulverized condition. S in which a = standard deviation n = number of measurements 85-011883/LTN-88 Table 3: Composition and calorific value of the briquettes and Eucalyptus Cotton Corn White Black coffee Wheat Encalyptus stalks stover coffee parchment husks (aggl.) straw Globulus moisture content (M) 5.88 5.70 5.36 9.10 7.60 6.84 ash content (%) 3.16 3.45 0.33 8.90 4.50 0.29 volatile content (%) 75.8 77.5 83.4 65.4 78.1 82.2 C-content (%) 47.1 47.1 50.1 47.8 47.5 47.46 N-content (%) 5.99 6.05 6.19 5.10 6.00 6.08 O-content (%) 43.9 43.5 42.7 36.0 42.6 45.82 N-content (M) 0.35 0.40 0.24 3.00 0.42 not determined sulphuric lignin (%) 21.5 17.16 25.1 37.2 17.6 not determined content (S = 0.4) (S = 0.06) (S = 0.3) (S = 0.3) (S = 0.2) gross calorific value (NJ/kg) 19.05 19.90 20.55 18.65 18.35 21.00 net calorific . value (NJ/kg) 17.80 18.65 19.33 17.60 17.10 19.75 The sulphuric lignin content of the non-agglomerated black coffee husks is 20.6% (S = 0.6) - all data are given on a dry-matter basis, except for the moisture content. * 39 - 4. PROPERTIES OF TIE ASHES The fusion behaviour of the ashes of all five briquettes has been examined by the Technical Laboratory Laura, Bygelshoven, The Nether* lands. Because ashes are heterogeneous mixtures of m1nirals of various com- positions they do not melt at a standard temperature but soften gra- dually. Therefore their fusion behaviour is characterized in terms of three characteristic temperatures, viz. the deformation tempera- ture, the hemisphere temperature and the flow temperature (2). The method applied to determine these temperatures comprises the ob- servation of the melting of an ash cube mounted on a Platinum sup- port in an oxidizing atmosphere (air), in accordance with the Inter- national Standard ISO 5,40-1981. At deformation temperature the first rounding of the vertices takes place, at hemisphere temperature the cube has assumed the shape of a hemisphere (i.e. its height equals .hal. its width), and at flowtemperature the cube's height has been reduced to 1/6 of its width. Table 4 presents the fusion points of the five ash samples. Because the cotton ashes started to soften already below 815 9C this sample was only heated to 500 OC, which may have caused the sample to con- tain some organic matter. The corn ashes contained some plastic par- ticles from a broken packing. Table 4: Characteristic points of the melting course of five ash samples Deformation Hemisphere Flow temperature temperature temperature (C) (C) (C) Corn stover 1100 1230 1370 Cotton stalks 720 > 1560 > 1560 Wheat straw 1110 1370 1410 White coffee parchment 1310 > 1560 > 1560 Black coffee husks (aggl.) 940 1200 1500 - 40 - The chemical composition of the ashes of the corn-, cotton- and white coffee briquettes was also determined, by means of a semi-quantitative emission spectrometric screen of the ashes. The relative accuracy of the data amounts to 20%. Table 5 presents the results in percentages by mass. The fusion behaviour of an ash cannot easily be correlated with its composition. However, some rough tendencies are known. The fusion points are generally lowered by an increase in the content if fluxing oxides (CaO, MgO, FeO, Fe203 etc.). In the case of a constant con- tent of fluxing oxides the fusion points may be expected to increase with the ratio Al203/SiO2 [2]. - 41 - Table 5: Chemical composition of the ashes of the cotton-, corn- and white coffee briquettes Element Cotton stalks Corn stover . White coffee (Vt. %) (Vt. %) parchment (Vt. %) K H > 10 M > 10 H > 5 Ca H > 10 M > 5 M > 10 Mg H (1-5) " > 5 H > 5 Si 0.7 H > 10 nH (1-5) Fe 0.3 nM (1-5) n (1-5) Al 0.3 ca. 1 nM (1-5) Na 0.5 0.06 0.6 Mn & 0.06 0.3 0.6 Zn b.m.c. < 0.1 b.m.c. < 0.1 0.3 Ti 0.03 0.2 0.2 Cu :S 0.01 S 0.02 ( 0.1 Ni 0.01 0.03 0.06 Ba b.m.c. < 0.06 b.m.c. < 0.06 0.2 B 0.04 S 0.01 0.08 Cr b.m.c. < 0.005 0.01 0.015 Pb b.m.c. < 0.01 b.m.c. < 0.01 0.01 Sr b.m.c. < 0.1 b.m.c. < 0.1 0.1 Sn < 0.005 < 0.005 < 0.005 V < 0.01 0.01 < 0.01 Zr b.m.c. < 0.01 b.m.c. < 0.01 0.01 Sb b.m.c. < 0.03 b.m.c. < 0.03 b.m.c. < 0.03 Nb b.m.c. < 0.03 b.m.c, < 0.03 b.m.c. < 0.03 Co b.m.c. < 0.01 b.m.c. < 0.01 b.m.c. < 0.01 W b.m.c. < 0.1 b.m.c. < 0.1 b.m.c. < 0.1 Cd b.m.c. < 0.01 b.m.c. < 0.01 b.m.c. < 0.01 Bi b.m..c. < 0.005 b.m.c. < 0.005 b.m.c. < 0.005 Ho b.m.c. < 0.005 b.m.c. < 0.005 b.m.c. < 0.005 Ag b.m.c. < 0.002 b.m.c. < 0.002 b.m.c. < 0.002 Be b.m.c. < 0.001 b.m.c. < 0.001 b.m.c. < 0.001 M = main component nH = secondary component b.m.c. = below measurable concentration - 42 - 5. DENSITIES The basic (or specific) density and the bulk density of the raw mate- rials were determined by C.R.A. Gembloux. The basic densities were determined by using a Breuil mercury volumenometer and constitute an average of 5 measurements. The standard error as well as the moisture content at the moment of testing are presented. The bulk densities were measured after drying and grinding of the raw materials had taken place, so the moisture content at the moment of testing was below 5%. The test-volume used was 0.003 i3. Table 6 shows the results. Table 6: Basic and bulk density of the raw materials moisture basic density standard bulk density content error ( (kg/M3) (kg/3) Corn stover 9.6 221 9 99 Cotton stalks 10.4 450 10 143 Wheat straw 8.0 380 50 97 White coffee parchment 9.2 920 30 100 Black coffee husks 12.6 1090 80 142 on a dry-matter basis The basic density of the briquettes was determined as follows: After the briquette had been weighed its volume was determined by immersing it in paraffin and by measuring the paraffin's volume displacement. Paraffin was chosen because it is barely absorbed by the briquett4s. Five fragments of briquettes from each material have been tested in this way. The spread in the results is quite extensive, especially in the case of the white coffee parchment briquettes, the cotton stalks briquettes and the agglomerated black coffee husks briquettes. Table 7 discloses the results. The standard error - which may be considered to constitute a measure for the accuracy of the mean value of the measurements - is given, and so are the moisture content on a wet- *matter basis of the briquettes at the moment of testing. The briquet- tes were exposed to the ambient for several weeks at the time. - 43 - Table 7: Basic density of the briquettes and Eucalyptus Basic density Standard Moisture content (kg/M3)* error Corn stover 990 20 3.1 Cotton stalks 1090 50 4.1 Wheat straw 1050 15 3.3 White coffee parchment 1240 70 3.1 Black coffee husks 1170 40 9.9 (aggl.) Eucalyptus 950 40 9.9 * on a wet-matter basis The bulk density of the briquettes was measured after they had been conditioned for 6 days in a climatic room at 23 OC and 50% relative humidity. The values given in table 8 are averages of three measure- ments with various test volumes'. Owing to the rather small quantity of briquettes available the shape and size of the boxes that were used had some influence on the measured values. Therefore the test- volumes applied and the standard error are given, the latter serving as a measure for the accuracy of the mean values. The briquettes in the box were allowed to settle by vibrating the box for some time. Table 8 also presents the moisture content of the briquettes at the moment of testing. For the corn-, cotton- and white coffee briquettes one measurement was done, after conditioning at 20 OC and 90% relative humidy, with a test volume of 0.024 i3. No such values could be obtained in the case of the agglomerated black coffee- and wheat straw briquettes, see section 6. The higher bulk density of the agglomerated black coffee husks bri- quettes should be attributed to the fact that a large part of the briquettes had crumbled. Table 8: Bulk density of the briquettes Conditioning at 23 OC, 50% relative Conditioning at humidity 20 OC and 90% r.h. bulk standard test moisture bulk moisture density error volume content density content (kg/a3) (10-3 in) M (kg/a3) (%) Corn stover 510 30 3.9;12.3; 9.9 3.8 460 9.4 Cotton stalks 530 10 3.9;10.1; 9.7 3.9 440 10.8 Wheat straw 500 10 14.0;14.9;12.1 5.0 * - White coffee 600 10 3.9;11.7;11.1 3.4 600 8.6 parchment Black coffee 680 20 20.0;12.1;14.4 7.8 - - husks (agg1. * 7. on a vet-matter basis. -45 - 6. STQRAGE IN A HUNID ATMOSPERE Table 9 shows the increase in the moisture content of the corn-, cotton- and white coffee briquettes during storage in a climatic room at 20 OC and 90% relative humidity. After 16 days the corn stover briquettes started to swell, the cotton stalks and white coffee parchment briquettes did not then show any signs of alteration yet. The corn- and cotton briquettes had reached a stable condition at the time, whereas the white coffee parchment briquettes may not have been stable yet. The transport simulation tests were carried out with these three materials in this particular condition. Table 9: The moisture content as.a function of time moisture content (% on a wet basis) t = 0 days t = 4 days t = 9 days t = 16 days corn stover 1.9 4.3 9.6 9.4 cotton stalks 2.5 4.5 10.5* 10.8 white cofee 1.9 4.9 6.8 8.6 parchment The agglomerated black coffee husks briquettes were put into the climatic room at 20 OC and 90% relative humidity with an initial moisture content of 9.9% (on a wet-matter basis). The briquettes appeared to have completely disintegrated after having remained in the climatic room for 7 days. Because of the limited quantity of material available, the wheat straw briquettes have not been submitted to conditioning at 20 *C and 90% relative humidity in order to save enough material to do a trans- port simulation test. Although the quality' of the wheat straw bri- quettes is slightly better than the quality of the agglomerated black coffee husks briquettes, it was utill expected that they would not survive the conditioning. The condition of 20 OC and 90% relative humidity may be considered to constitute a "worst case" of the conditions occUrring in Ethiopia. - 46 - This is illustrated by table 10, in which the average humidity per month is given, measured daily at 07.00 hours in Addis Abeba and Gimma. This is the time of day when the relative humidity is general- ly at it's maximum. The choice of the 20 oC, 90% r.h. level was rela- ted to the levels of conditioning applied prior to the transport si- mulation tests (see section 7). Table 10: Relative humidity 1, Addis Abeba and Gimma month relative humidity (%) month relative humidity (%) Addis Abeba Gimma Addis Abeba Gimma Jan. 61 53 July 64 77 Feb. 58 61 Aug. 65 79 Mar. 63 63 Sept. 76 78 Apr. 86 66 Oct. 86 67 May 79 74 Nov. 56 53 Jun. 59 78 Dec. 62 52 The data of Gimma are averages over 2 years; of Addis Abeba over 12 years. source: KNMI, de Bilt, the Netherlands. The following conclusion may be drawn: The corn stover-, cotton stalks- and white coffee parchment briquettes withstood storage at 20 oC and 90% relative humidity for 16 days, showing only minor signs of deterioration or none at all. In this context the corn stover briquettes appear to be slightly more sensi- tive to moisture than the cotton stalks and white coffee parchment briquettes. The agglomerated black coffee husks briquettes have a poor resistance to moisture, and this same conclusion is expected to hold for the wheat straw briquettes while these are only of slightly better quali- ty than the agglomerated black coffee husks briquettes. The salient difference between the results with the conical screw press briquettes - the former three - and piston press briquettes - the latter two - should not be generalized. It is beyond discussion that the agglomerated black coffee husks briquettes and wheat straw briquettes are not the best quality briquettes that may be produced by a piston press. The bad results may thus have little significance to the production method. - 47 - 7. TRANSPORT SINULATION TESTS The transport simulation tests were carried out by the Institute TNO of Packaging Research, Delft, the Netherlands. Prior to exposing bri- quettes to mechanical treatments that simulate real-life transport and handling, the briquettes have to be conditioned. Based on the International Standard ISO 2233, part 2, "Conditioning for testing of complete, filled transport packages", two levels of conditioning were selected from the list of standard levels, namely 20 OC, 90% relative humidity (r.h.) and 23 *C, 50% r.h. These levels are commonly applied for conditioning prior to simulation of transport under tropical and subtropical conditions. Unfortunately the quantity of briquettes pro- duced was too small to do tests at both levels of conditioning. Because it was expected that a "worst-case" experiment would give the most useful information it was decided to condition the briquettes at 20 OC and 90% r.h. before exposing them to the mechanical trea.tments. The quantities of briquettes that were delivered to the Institute TNO of Packaging materials were the following: - corn stover 80 kg - cotton stalks 15 kg - wheat straw 50 kg - white coffee parchment 32 kg - agglomerated black coffee husks 40 kg The briquettes were tested in thin gunny bags of 50 x 100 cm and 305 gr. of gunny/m2 quality. The bags were filled with 40 kg of briquettes. Some spruce briquet- tes, produced by a conical screw press, and.with a diameter of 30 mm, were added to the quantities of cotton stalks briquettes and white coffee parchment briquettes In order to attain the 40-kg filling mark of the bag. The bags were sealed by means of a joggle. The three screw-made materials, i.e. the corn-, cotton- and white coffee briquettes were conditioned for 16 days at 20 OC and 90% re- lative humidity. It was attempted to submit the agglomerated black coffee husks briquettes also to the above-mentioned treatment, but after 7 days the briquettes had completely disintegrated. Meanwhile, - 48 - 20 kg of agglomerated black coffee husks briquettes had been set apart and were submitted to a reduced set of mechanical tests after having been conditioned at 23 *C and 50% relative humidity with an additional filling of unconditioned spruce briquettes up to 40 kg. Finally, the wheat straw briquettes were also submitted to a reduced set of mechanical tests in order to gain a better insight into the friability of the piston-made briquettes. The wheat straw briquettes were tested without prior conditioning. The moisture content of the briquettes at the moment of testing is set out in table 11. The mechanical treatments to which the briquettes were submitted com- prised the following tests: 1. rotating-drum test: . drum diameter : 4.20 m " number of rotations : 4 (i.e. 24 falls) 2. free-fall test: falling height : 1.20 a Snumber of falls : 5 1st: perpendicular, on the bottom of the bag. 2 nd: flat, on a lateral face of the bag. 3nd: perpendicular, on the filling side of the bag. 4th: at an angle of 45 degrees on the filling side of the bag. 5 th: perpendicular, on the bottom of the bag, but on a log of 10 x 10 cm. 3. vibration test: . position of the bag on the vibration table: vertical . direction of the vibrations : vertical . duration of the vibrations : 30 min. . intensity of*the vibrations : about 5 Rz and I G, i.e. so that the bag gets only just lifted off the table. . load of the bag : corresponding with a truck load of 2.2-i height, by means of an intermediate layer of spruce briquettes filled up with bags of sand or steel sheet (120 kg in all). - 49 - The mechanical tests no. I and 2 represent a standard programme for simulating various ways of transporting general cargo all over the world, handling by hand included. The mechanical test no. 3 adds the effects of a truck load and the prevailing bad conditions of roads in developing countries to the above. As has been mentioned before the agglomerated black coffee husks briquettes and wheat straw briquettes were only submitted to a re- duced set of tests. The agglomerated black coffee husks briquettes had been pulverized for 95% after test no. 1. Consequently, there was no need for the other tests to be carried out anymore. The wheat straw briquettes were only exposed to tests no. I and 2, essentially for the same reason. The effects of the mechanical treatments on the briquettes are presented in table 11. Table 11: Results of the transport simulation tests moisture exposed pulver fragments up to fragments above content to tests 3 cm length 3 cm length (%) 1) nrs. ( 2) 2) 2) corn stover 9.4 1,2,3 13 35 * 52 cotton stalks 10.8 1,2,3 20 30 50 white coffee 8.6 1,2,3 20 39 41 parchment black coffee husks 7.8 5) 1 9 5 3)- wheat straw (aggl.) 3.3 6) 1,2 50 50 4) 1) % on a wet-matter basis. 2) % by mass relative to the initial mass of briquettes. all fragments that could be distinguished from pulver. 4) all fragments*above 1-cm length. 5) after conditioning at 23 OC, 50%-r.h. 6) without prior conditioning. From -table 11 it is clear that the resistance to mechanical shocks due to handling and transport of the three screw-made briquettes from corn stover, cotton stalks and white coffee parchment is remarkably - 50 - better than the resistance of the two piston-made briquettes from wheat straw and agglomerated b,lack coffee husks. Though former expe- riences with screw-made and piston*-made briquettds of the same mate- rial indicate this same tendency from the present data no general conclusions may be drawn about the difference between screw-made and piston-made briquettes. Firstly because to briquettes of the same material produced by either method were available. Secondly because the quality of the wheat straw and agglomerated black coffe husks briquettes was not optimal - as was mentioned before. With respect to the particular briquettes tested the following con- clusions may be drawn: - After their storage in a humid atmosphere (90% r.h), followed by handling and transport, between 40 and 80% of the corn-, cotton- and white coffee briquettes may still be usable as fuel for domes- tic purposes. It can be expected that the output will be even bet- ter under more favourable atmospheric conditions. - From the materials that were tested, the corn stover briquettes appear to have the-best resistance to mechanical shocks. - These porticular agglomerated black coffee husks briquettes, which were already of poor quality even before they were exposed to any mechanical test, must be considered absolutely unsuitable to serve as fuel for domestic purposes, because any mechanical load reduces the briquettes to pulver. - After handling by hand and transport under conditions as found in the western hemisphere in a relatively dry atmosphere have taken place, less than 50% of these particular wheat straw briquettes . may be considered usable as fuel for domestic purposes. - 51 8. COMBUSTION TESTS 8.1 Test procedure and equipment The combustion tests were performed in a domestic cooking stove, de- signed and manufactured by the Woodburning Stove Group, Eindhoven, the Netherlands. It concerns a cylindrical one-hole metal stove with grate and without chimney, see fig. 2. A diafragm forces the flue gases to flow initially to the middle of the pot bottom and then through a one-cm wide gap along the pot bottom and -sides. A flat bottomed aluminium pot with a 22.8-cm inner diameter was used. When filled to about 3/4 of its height, the pot contained about 3 kg of water. During the tests the pot was covered by a lid. The test procedure applied to investigate the combustion of the bri- quettes constitutes the water boiling test. A known quantity of water is brought to boiling point and is kept boiling for at least 30 mi- nutes. The energy absorbed by the water may be calculated from the quantity of water that has evaporated and the temperature rise of the initial quantity of water. The energy that was supplied by the fire may be calculated from the measured quantity of fuel burnt du- ring the test and its calorific value (corrected for the moisture content of the fuel). The ratio of absorbed and supplied energy makes out the cooking efficiency. The accuracy of the efficiencies is found to be in the order of 10%, due to the spread that usually occurs in cases of these particular types of experiments. With each material a high power water boiling test and a low power water boiling test was carried out. Because a solid fuel combustion process is essentially a non-stationary process with a fluctuating power output level, the fuel loading procedure which was different for the high power- and the low power tests requires some explanation. - 52 - 0A -T 7L A A TOP VIEW 240 145 grill with 52 holes steel plate, of 0 15 m thickness- lm 60 02SO /primary air-holes i * CROSS SECTION A-A FRONT VIEW scale 1:5 (dimensions in mm) MT-TNO Dimensions of the stove 13801 Fig. 2 - 53 - The high power tests were performed according to the batchwise fuel loading procedure generally applied by the Woodburning Stove Group [3]. This means that equal charges of fuel are loaded at equal inter- vals of time. The power output is then considered to be the ratio of the energy content of one charge of fuel and the time between the addition of two charges (see section 8.2). Fig. 3 illustrates this batchwise procedure; it shows the reduction in the fuel mass as a function of time for a high power test with wheat straw. Notice that the course taken by the gas concentrations also clearly reflects the batchwise fuel loading procedure. The high power tests were carried out in such a way that there was hardly any build-up of the fuel bed. The low power tests were carried out according to a procedure resem- bling the procedure described by the provisional International Stan- dards for the testing of cooking stoves [4]. The experiment is ini- tiated in the same way as the high power tests. At the moment when the water reaches boiling point it is weighed and put back on the stove. It is then kept boiling for about one hour, using as little fuel as possible. The fuel is freely added at moments judged opportune by the experimenter. However, it appeared that fragments of briquettes had to be added regularly (almost batchwise) in order to prevent the water- temperature from dropping below 97 OC. This is very well illustrated by fig. 4, which presents the reduction in mass as a function of time for a low power experiment with white coffee parchment. The average power output during the simmering period is calculated from the over- all efficiency, the total quantity of fuel burnt during the test, the calculated energy that was necessary to bring the water to boiling point and the measured boiling time (see section 8.2). The main difference between the procedure described above and the procedure described by the provisional standards is that the low power phase is started directly after the moment when the water reaches boiling point and the water - instead of the fuel - is weighed at the end of the high power phase. Apart from the fact that this procedure is far more convenient to the experimenter, the problem of distin- quishing between initial fuel and charcoal is also -avoided in this way. - 54 - Watertemp. mass of fuel mass of fuel 4m 0 loter (kg) 0.3temP. t ~(OC 0.2 8 0.1 .60 0 1 I - 80 0, 2I -0 7. .0 !..0 II 0.1 /* ia I 0. / 30 60 . -- time (min) I' 1.2 .1 CO (%.0 C w.7 -e jtr. ' - 3 0.20 0,/1 0.3 1.I0 0.00 60 --+ time (min) Reduction of the mass of.fuel and the CD and 002 concen- MT-TN0 trations as a function of time for a high power experiment I 13801 with wheat straw I Fig. 3 -55 - water - weighing of the water temp(c) ~\ #~- 100 mas& of i. . fuet (kg) i w tr m . 9 ..---Wcxtrtelmp. \ ----- mass of fuel i 80 0.2 - l 60 0,1jI 0.0 40 30 60 90 120 timet(min) ID - 20 9.0 CO2 0%) I CO27.0 -- -co -50 4,0 to \ r (%) Il2ß 0.3 - 0,2 ,nI -0.0 0 30 60 90 120 - time (min) Reduction of the mass of fuet and the CO and C02 con - MT-TNO centrations as a function of time for a low power ex - 13801 periment with white coffee parchment Fig. 4 - 56- During all experiments' a gas analysis was made by means of the gas sampling system shown in fig. 5. A gas sample is sucked at various points along the gap between pot side and stove wall. Before entering the analysers the flue gas sample passes a condensation pot, a parti- cle filter and two cooling elements. The levels of carbon monoxide and carbon dioxide are therefore measured on a dry flue gas basis. The levels presented in the report are average concentrations over the duration of the test. The rombustion quality may conveniently be expressed by the ratib of the CO- and CO2-concentration, because this value is independent of the measure of dilution of the flue gas samples. In order to make a fair comparison between the various fuels the quantity of carbon monoxide produced per useful quantity of heat was also calculated (see section 8.2). The ease of ignition, smoke production, odour and cohesion of the briquettes during the combustion process were not determined quan- titatively, but a sensory judgement was passed on the basis of com- parison with results from similar tests with Eucalyptus Globulus. The Eucalyptus was burnt in fragments of 2.4 x 2.8 x 10 ca. 8.2 Some definitions The cooking efficiency-is defined as the ratio of the energy absorbed by the water (or food) and the energy supplied by the fuel: m C(Tb - T) + m L n = R 100% (8.2.1) ii = cooking efficiency [%] a%= initial mass of water [kg) me= mass of evapokated water [kg] m= total mass of consumed fuel [kg] C specific heat of water [kJ/kgK) Tb : boiling temperature of water [oC] T. = initial water temperature [OC] L = evaporation heat of water at 100 OC and 105 Pa [kJ/kg] II net calorific value of the fuel [kJ/kgJ * 57 - .t16 inlt tubes of the periphery *-:::--..f I- uftu gas sample IP E-- ** * , n Pelttler ..- - ** - -cooler flue gas stram gas analysers 02. * 02 * CO data acquisition and proiessing Experimental set-up of the gas analysis system MT-TN0 13801 FIq. 5 - 58 ' The following numerical values are used: C = 4.19 kJ/kgK L = 2256.9 kJ/kg The average power output of the fire over a certain period is the amount of heat released by the fire per unit of time. m H P= (8.2.2) t P = power output [kW] m = total mass of fuel consumed during period t [kg] H = net calorific value of the fuel. [kJ/kg] t = period of time [s) In case a batchwise fuel loading procedure is applied the power out- put may be defined as: Am .H P = A(8.2.3) At Am = mass of a charge of fuel [kg] At = interval between the addition of successive charges of fuel [s] The calculation procedure applied to determine the average power out- put during the simmering period of the low power tests reads as fol- lows: (mf . H - Eb/nt s 3 (tt tb) P = power output during the simmering period [kW] t f total mass of .fuel burnt during the test [kg) t t= efficiency over the whole test .[%/100] tt duration of the whole test [s] tb = time required to bring the water to boiling point [s] E-b =energy required to bring the water to boiling point in the case of 100% efficiency JkJ] - 59 - Eb is calculated from: Bb v . C (Tb - Y + e (100 C) L (8.2.5) m = initial mass of water me (100 OC) = mass of water evaporated at the moment when the water starts to boil. In this calculation it is assumed that the overall efficiency nt is valid for the period before the water starts to boil as well as the simmt-tng period. The carbon monoxide production per useful quantity of heat for a cer- tain fuel/stove combination may be derived from: pCO = (8.2.6) Ch H .rA p = CO 'production per useful quantity of heat [kg/useful NJ] COh h ih which: p =C CO .28(827 PCO 12 Co + co (8.2.7) m 2 pCO = CO production per kg of fuel [kg/kg of fuel] a C ' = mass fraction of carbon [%1100] CO, CO2 = average gas concentrations [%) In this calculation it is assumed that the quantity of hydrocarbons, formed during combustion, is negligible. Cases in point bear out the theory. 8.3 Results and discussion The net calorific values of the briquettes, corrected for the pre- vailing moisture contents during the combustion tests, are given in table 12. - 60 - Table 12: Corrected calorific value of the briquettes and Eucalyptus calorific value (MJ/kg) Corn stover 18.30 Cotton stalks 17.36 eat straw 16.46 ite coffee parchment 18.93 lack coffee husks (aggl.) 15.63 ucalyptus G. 18.25 The results of the high power tests are set out in table 13. The agglomerated black coffee husks generate a significantly lower effi- ciency than is obtained from the other fuels. Ignition proved very difficult and it was also hard to keep the fire going. The flames disappeared very quickly compared to the other fuels. The briquettes also disintegrated during the combustion process, so that smell frag- ments of unburnt fuel fell through the grate, in this way causing a loss of fuel on the one hand and blocking the air flow through the grate on the other hand. Notice that the agglomerated black coffee husks had the highest ashcontent and the lowest vdlatile content. The other fuels do not differ a great deal. The white coffee parch- ment briquettes and Eucalyptus give slightly higher efficiencies and power output levels than the corn- and cotton briquettes, which in their turn contained slightly more ash than the other two. The wheat straw has a lower power output than the other fuels, except for the agglomerated black coffee husks briquettes. This phenomenon cannot be accounted for by a significantly higher ash content of the wheat straw; however, it should be noticed that the wheat straw briquettes had a diameter of 50 mm set against a 30-m diameter of the corn-, cotton- and white parchment briquettes. Apart from the agglomerated black coffee husks briquettes none of the fuels disintegrated during combustion. They neither smoked excessively nor significantly less than wood. No extraordinary odour was noticed. Because of their volatile content the briquettes burn liku wood rather than charcoal. The volatiles initiate the first combustion phase which involves yellowish flames. 85-011883/LTN-88 Table 13: Results of the high power water boiling tests symbols: n - number of charges t - duration of the test (min) f - total mass of fuel (kg) tb - boiling time (min) a - initial water quantity (kg) P - power output level (kW) Ti. - initial water temperature (OC) q - cooking efficiency (M) m e - mass of evaporated water (kg) n f mi T me tt t P q (kg) (kg) (0C) (kg) (min) (min) (kW) (M) Corn stover 4 0.8081 2.946 27.1 1.559 67 8 3.7 29.9 Cotton stalks 4 0.8013 2.946 25.6 1.344 56 11 4.1 28.4 Wheat straw 4 0.6861 2.947 17.2 1.043 66 31 2.8 29.9 White coffee 4 0.8055 2.946 25.6 1.733 52 8 4.9 31.7 parchment - Black coffee 4 0.6640 2.946 18.4 0.369 67 (T = 88 OC) 2.6 16.3 e husks (aggl.) ucalyptus 2 0.4750 2.800 20.0 0.860 32 10 4.5 33.2 - 62 - Table 14 presents the results of the low power water boiling tests. The best results were obtained with corn stover, wheat straw and white coffee parchment. In the case of the cotton stalks briquettes a very low power output was obtained. However, compared to the high power test the effiAency was quite low. From the gas analysis re- sults it appears that a great deal of carbon monoxide is produced per useful quantity of heat, see table 15. This constitutes a poor com- bustion quality indicating that the power output has been too low. In the case of a somewhat higher power output the cotton briquettes may be expected to behave similarly to the corn-, wheat- and white coffee briquettes. The white coffee parchment briquettes perform best; their ratio of high and low power output level is 3.5, which is considerable for the rather small stove used. The agglomerated black coffee husks briquettes and the Eucalyptus are difficult to burn at a low power level, however for quite different reasons. Ignition of the agglome- rated black coffee husks briquettes is poor, as has already been no- ticed. Eucalyptus however burns fiercely so that a lower burning rate could not be obtained. The gas analysis results are set out in table 15. It is obvious that the combustion quality of the agglomerated black coffee husks briquettes is poor, especially during the high power test. The carbon monoxide production per useful quantity of heat is for all other fuels higher at a low power level than at a high power level. The white coffee parchment has the best combustion quality in terms of carbon monoxide production, an even better quality than Eucalyptus supplies. Fhe corn stover and cotton stalks briquettes, and the Eucalyptus do not differ significantly at a high power level, but only the corn stover briquettes maintain a low CO-production at a low power level too. The moisture content of the Eucalyptus used was 6.8%, which may be lower that the moisture content of the Eucalyptus prevailing in Ethiopia. If Eucalyptus of a higher moisture content would have been used the conclusions described in this section had not been signifi- cantly different. Experiments conducted in the framework of the Woodburning Stove Group programme 131, have shown that the efficiency does not change more than within the range of the spread, using wood with moisture contents up to 30%. The carbon monoxide production also 85-0 11883/LTNI-88 Table 14: Results of the low power water boiling tests symbols a - total mass of fuel (kg) me - quantity of water evaporated during the test (kg) I - initial water quantity (kg) t - total duration of the test (win) * initial water temperature (C) tb - boiling time (ain) e (100 OC) - quantity of water ps - power output during the simmering period (kW) evaporated when the - total efficiency (M) water reaches boiling point (kg) I f T me (100 OC) me at tb Ps (kg) (kg) (oC) (kg) (kg) (win) (win) (kW) () Corn stover 0.6845 2.946 25.7 0.166 1.028 98 20 1.6 25.8 0 Cotton stalks 0.9428 2.946 16.9 0.371 1.133 171 68 1.3 21.9 Wheat straw 0.7335 2.946 14.2 0.139 0.966 104 22 1.4 26.8 White coffee 0.6898 2.946 20.0 0.240 1.125 117 29 1.4 27.0 parchment Black coffee 1.0215 2.946 26.0 0.172 1.290 93 45 1.9 23.9 husks Eucalyptus 0.9213 2.946 17.3 0.170 1.285 121 42 2.3 23.3 the water temperature dropped below 97 OC several times 85-011883/LTN-88 Table 15: Gas analysis data of the water boiling tests corresponding with the data presented in table 13 and 14 symbols CO2 - average CO2-concentration luring the test (%) CO - average CO -concentration during the test (%) High power tests Low power tests CO2 CO CO/CO2 gr. CD/ CO2 CO CO/CO2 gr. C/ (M) (M) useful NJ (M) () useful RJ Corn stover 5.9 0.4 0.07 13 3.0 0.2 0.06 14 Cotton stalks 4.6 0.3 0.06 12 1.8 0.2 0.13 32 Wheat straw 3.2 0.3 0.08 17 2.6 0.3 0.10 22 White coffee 5.6 0.2 0.03 6 2.3 0.1 0.06 12 parchment Black coffee 2.4 0.3 0.13 51 3.1 0.3 0.10 28 husks Eucalyptus 3.5 0.2 0.06 10 2.4 0.2 0.09 21 . for the calculation the corresponding efficiencies from table 13 and 14 were used. - 65 - does not differ significantly when wood with moisture contents up to 20% is burned, in the case of 30% m.c. it may be expectel that sligthly more CO will be produced. As for the power output again minor changes were observed, except for the 30% m.c. case. The low power level of 2.3 kW obtained with the Eucalyptus of 6.8% m.c. can be expected to become somewhat lower if Eucalyptus of 30% m.c. would be used. In summarizing the foregoing discussion the following conclusions concerning the combustion of the briquettes may be drawn: * The white coffee parchment briquettes perform best: they allow for a high power ratio, a good efficiency, both at high power level and low power level and generate a considerably lower carbon monoxide production per useful quantity of heat then Euca- lyptus. - These particular agglomerated black coffee husks briquettes give poor results: ignition is poor, which causes quite an amount of smoke, the power may barely be varied, cooking efficiency is low and carbon monoxide production is high. Moreover, the briquettes disintegrate during the combustion process. - The results reached with the corn stover briquettes, the cotton stalks briquettes and the wheat straw briquettes are comparable to those with Eucalyptus. At a high power level they perform slightly worse, and at a low power level slightly better. In the case of wheat straw it is more difficult to attain a high power level. - The corn-, cotton-, wheat- and white coffee briquettes may serve as fuel for domestic use: the combustion results are comparable to, or sometimes even better than those reached with Eucalyptus, ignition is good, they do uot smoke significantly more, or less than Eucalyptus and they keep their shape during the combustion process. Because of their volatile content the briquettes burn like wood rather than charcoal. - 66 - 9. CONCLUSIONS AND RECOMMENDATIONS The conclusions about distinct properties of the briquettes presented in the foregoing sections of this report may be put together in a few general conclusions. These should be viewed in the light of the specific constraints under which this research programme was carried out. It was attempted to compress all residues by a conical screw extruder. Good briq.-ttes resulted from the corn stover, cotton stalks and white coffee parchment, but the compression of the wheat straw and non-agglomerated black coffee husks was unsuccessful. Therefore those materials were compressed by a hydraulic piston press. Because the preprocessing of the materials had taken place in accordance with the specifications imposed by the conical screw extruder the characteristics of the material fed into the hydraulic piston press were not optimal. Moreover, black coffee husks were produced only from the agglomerated species. The results obtained with the latter briquettes may not be valid for the non-agglomerated species of black coffee husks. The conclusions are the following: 1. During the compression with the comical screw extruder the non- agglomerated black coffee husks and the wheat straw appeared to behave differently from the corn stover, cotton stalks and white coffee parchment. Too low a friction was generated in the case of the former two materials, whereas good quality briquettes, were produced from the latter three materials, at the same working conditions' of the equipment. This cannot be explained from large differences in the lignin content of the materials. 2. The quality of the briquettes from the wheat straw and the agglo- merated black coffee husks, which were produced by a hydraulic piston press, cannot be termed representative for the quality that is,obtainable with this production method (on the basis of comparison with known compression results of e.g. wood wastes). Therefore the results with these briquettes do not apply to "piston-made" briquettes in general and the salient difference in the results with respect to shock- and moisture resistance of the "screw-made" and "piston*made" briquettes may-not be generalized. - 67 - 3. The briquettes from corn stover, cotton stalks and white coffee parchment - i.e. the briquettes that were produced by the conical screw extruder - are most likely to be suitable to serve as fuel for domestic use. Their resistance to storage in a humid at- mosphere, followed by mechanical treatments simulating handling and transport is quite good - up to 80% output. It may be expec- ted that the output will be even better under more favourable atmospheric conditions. Their combustion performance is compara- ble to, or even better than the performance of Eucalyptus. 4. The suitability of the particular wheat straw briquettes tested, to serve as fuel for domestic use must be doubted. Although their combustion performance is quite good, their resistance to mecha- nical treatments, even in dry condition, is only very moderate (maximum ouitput 50%). 5. The particular agglomerated black coffee husks briquettes that were produced during this project, are not suitable for use in domestic cooking because they are of a very poor quality in every respect. Their combustion performance is poor, low cooking efficiencies are obtained, their ignition qualities are poor and the briquettes disintegrate during combustion. The effects of storage in a humid atmosphere and olf any mechanical treatment, even in dry condition, are disastrous. 6. The usefulness of the briquettes for other than domestic purposes will strongly depend on the process under consideration. There- fore no general conclusions may be drawn on this point. In view of conclusion 2 it is recommended t .at the shock- and mois- ture resistance of similar materials produced by a conical screw ex- truder on the one hand and by a piston press on the other hand be examined more closely in order to provide a sounder basis for the choice of compression systems under various circumstances. In view of conclusion 4 it is recommended that the-compression poten- tials of the wheat straw be examined more closely. - 68 - LITERATURE [1] Living Trees of the World - T.H. Everett Doubleday Company Inc., New York (1966). [2) Technical Data on Fuel - J.W. Rose and J.R. Cooper World Energy Conference, London (1977). [3) Technical aspects of wood burning cookstoves - K. Krishna Prasad and E. Sangen ed. A report from the Woodburning Stove Group (1983). [4] Testing the efficiency of woodburning cookstoves * Provisional Inter- national Standards formulated at Arlington. A Vita publication (1982). - 69 - AM=E 3 EXCERPTS FROM COMBUSTION CONSULTANT'S REPORT ON BRQUETTES AS AN INDUSTRIAL FUEL FOR ETHIOPIA CONSULTANT: Robert A. Chronowski DATE: July, 1985 - 70- TABLE OF CONTENTS Ndge Assumptions and Constants used for Financial Analysis................1 I. Suunary of Findings..............................................3 II. Site Viit............. ............................... 7 III. Supplemental Industrial Users for Briquette Fuels.............13 IV. Prioritization of Industrial Applications......................17 - 71 - Assumptions and Constants Used for Financial Analysis - 1 US$ = 2.07 Birr - Where fuelvood must be harvested, the harvesting cost is estimated as US$7.00 per tonne - Puelwood as used air-dried to 20-25% MCNB has a heat value of 14.3 NJ/kg - Briquettes have an average as used heat value of 18.6 NJ/kg - Fuel oil in Ethiopia has a heat value of 40.1 NJ/liter - Ex-factory cost of briquettes US$/Tonne Coffee (Addis Ababa) - 31.22 (New Site) Coffee (Dila) - 37.04 Cotton (Awash) - 82.06 Wheat (Diksis) - 79.28 Corn (Nekempte) - 108.46 - Combustion efficiency drop when substituting briquettes for fuel oil = -5 to -10% - Combustion efficiency improvement when substituting briquettes for fuelwood - +5 to +10% - 1 m3 fresh cut green wood = 700 kg stacked for transport - 1 m3 air-dried fuel wood stacked - 500 kg at 25% mcwb - All briquette transport costs vary according to road conditions but generally follow 0.22 Birr per tonne km on asphalt to 0.58 8irr per tonne km on poor gravel roads (based on 22 tonne trucks) - Equivalent Cost: The term used in this report is simply the financial value of the fuel displaced divided by the tonnes of briquettes to be substituted - 72 - - Distance@ from briquette production sites to potential end use sitest Production Site Use Site Distance (km) Coffee (Addis) Addisa/ Muger 100 Ambo 120 Nazareth 110 Nura Era 150 Awara Melka 220 Dire Dawa 380 Coffee (Dila) Addis Ababa 330 Awasa 75 Muger 430 Wheat (Dixis) Addis Ababa 220 Nazareth 90 Muger 300 Nura Bra 130 Awara Melka 200 Dire Dawa 360 Cotton Residues Dire Dawa 130 (Awash) Awara Melks 100 Nura Era 175 Addis Ababa 270 Muger 370 Ambo 390 Corn (Nekempte) Ambo 130 Addis Ababa 260 Huger 270 a/ Assume flat rate charge of 10.00 Birr per tonne for delivery within Addis Ababa Aetro area. - All combustion calculations in this report are based on operations in the existing mode. Conservation initiatives which could easily save 20-30% or more are not considered when defining fuel require- ments. - 73 - I. Summary of Findings 1.1 The potential users of briquette fuels were categorized as either Level 1 which would require no modifications to utilize the briquettes as fuel, and Level 2 which would require relatively simple modifications to accept the briquettes as fuel. 1.2 Main Conclusion: Because the existing fuelwood and charcoal shortages are causing significant procurement problems for industrial users of these fuels, there is sufficient demand for the briquettes in industrial applications to fully utilize the potential briquette output of the Energy I Pilot Projects. A total Level 1 demand of 21,000 tonnes of briquettes has been identified along with a Level 2 demand that ranges as high as 73,150 tonnes additional. The total potential demand identified thus far is therefore 94,150 tonnes. 1.3 There are definite least cost options for the briquettes that potentially will be produced. The prioritized list of potential consumers is given in Table 1.1. The intent of the list is to combine the users with least cost producers (including the transportation costs), to choose users who will reap the most financial returns, and to adequately cover the industry base such that after the Energy I Pilot Projects are completed, a rapid expansion of both production and industrial consumption of the fuels can proceed strictly on merit, with no further testing or demonstration required. 1.4 All of the industries identified as Level 1 candidates use grate or pile burning, and with the exception of the lime kilns, are best supplied with briquettes of at least 5 cm in diameter and up to 50 cm in length to simulate the dimensions of the fuetwood normally used. The - 74 - lime kilns would best be served by say a 5 cm I 5 cm briquette to better simulate the charcoal normally employed. 1.5 The boiler modifications recommended to achieve a Level 2 status 1/ are based on retrofit with manually fed, solid fuel gasifier burners. The cement plants are more complex and require more extensive modifications. Several options exist for retrofitting the cement kilns and/or preheaters. 1.6 The Level 2 candidates presented in this report most likely do not represent the total potential market for the briquettes as not every industrial site could be identified and visited during the short mission. The market will make itself known as the briquette fuels become available and are successfully used. Th "major" constraint to Level 2 conversions to briquette fuels is the eluct- boiler program which has made significant capital investments in hardware in such industrial applications as: a. Pulp and Paper Plant b. Brewery c. Multiple Textile Plants d. Tyre Plant e. Hotels f. Schools g. Oil Mills 1/These would include ECAFCO, ETHARSO, St. George's Brewery, Addis Tyre Company, Akaki Textiles, Modjo Textiles, and Dire Dawa Textiles. Table 1-1 Priority Sites for Industrial Use of Briquette Fuels Industry Fuel Displaced Briquettes Substituted Equivalent Cost Briquettes Delivered Price Cost of Type-Amount-Value (S) (tonoes/year) (S/tonne) of Briquettes (S) Modifications National Alcohol Fuelwood-540003-193,801 2000 96.90 36.05-71.70 - Distillery Two Private Fuetwood-8000o3- 437,696 3625 141.28 36.05-140.34 - Brick Kilns Fuel oil-288,0001-_ 74.43 Aware Malke Fuetwood-34403 - 150,620 a/ 1225 122.96 65.65-113,71 Tobacco Barns Ambo Lime Kilns Fuel ol-561,0001-145,000 810 179.00 45.71-128.81 --- ETHARSO Fuel oil-726,0001- 187,638 2180 95.05 36.05-71.70 100,000 Fuelwood-1500m3k 1.M- United Oil and Fuelwood-25,000 3-N.A. 7875 b/ 115,03 based on 36.05-113.94 - Soap Mill Electricity-40 Owh-1.2 million electricity use Dire Dawa Fuel-1 fillionl-258,460 2270 113,86 77.11-97.76 100,000 Total Briquette Demand for Priority Users: 19,985 tonnes/year a/ As only 25% of the 3440m3 can be obtained, the analysis underestimates the value of the fuelwood, as not being able to purchase causes direct and tangible losses* b/ Not all of the 40 Gwh can be substItuted for; fulI substitution would require 9900-10,000 tonnes. -76- 1.7 There will be some resistance to additional capital investment to allow the use of briquette fuels regardless of the financial and economic implications. Using kWh charges of US$0.03 (LRNC) and US$0.06 (economic cost) results in the briquettes saving money at costs less than $115.03 and $230.06 per tonne respectively. If the new tariff for the industrial customers equals or exceeds the LRMC, there will be definite financial pressures to switch to less expensive fuels, hence briquettes. 1.8 It is also likely that additional Level 1 users will emerge who can utilize the briquettes with no modifications. One obvious class of use would be bakeries which are located in the major population centers and who could easily use briquettes in their wood-fired ovens. A bakery demonstration should be set up in Addis Ababa once the briquettes become available. The demonstration could be then publicized to motivate a demand from this sector that could approach 675 tonnes of briquettes per year in Addis Ababa. For an industrial program these smaller users should not be the project focus, but should be accounted for as potential demand as the briquette production is scheduled to expand following successful Energy I Pilot Project Demonstrations. 1.9 A visit to TMO in Apeldoorn, Holland to review the results of transportation and combustion tests confirmed that the physical and combustion characteristics of the briquettes are suitable for industrial applications. Relatively high net heating values were determined to range from 17.8 NJ/kg for cotton stalk briquettes to 19.3 NJ/kg for coffee parchment briquettes. Ash contents ranged from 0.33 to 3.45% with moisture contents between 5.36 and 5.88%. - 77 - II. Site Visits 2.1 Preliminary meetings were held with the appropriate ministries at the beginning of the mission and a priority list for plant visits was established from preliminary data available. The list prepared was as follows, and is graphically presented in Figure 2-1. In and around Addis Ababa% National Alcohol Distillery Ethiopian Cement Corporation (Addis plant) Ethiopian Hardwood and Softwood Board Plant (ETHARSO) Ethiopian Chipwood and Furniture Plant (RCAFCO) Ethiopian Plywood Plant Edget Oil Mill Two Private Brick Plants Two Ethiopian Brick Plants (Government) East of Addis Ababa: Dire Dawa Cement Plant Awara Nelka Tobacco Barns Awara Melka Fruit Canning Plant Vura Bra Tobacco Barns - 78 - West of Addis Ababa: Muger Cement Plant Ambo Lime Kilns South of Addis Ababa: Tobacco Curing Barns (Awasa) 2.2 As per the request of Matthew Mendis, made on a previous World Bank mission, the Ministry of Industry had prepared a list of the annual fuel consumption for those industries that currently utilize fuelwood. The above list of visits was prepared based on that available data. Upon visiting the respective plants, it was discovered that the fuelwood consumption data supplied to the Ministry by each plant was uniformly exaggerated by 20 to 100Z. The explanation would appear to be that the obtaining of fuelwood is by means of a tedious and time-consuming permit process. Industrial users exaggerate consumption to either reduce the number of fuelwood procurements per year, or, more likely, to build up some amount of inventory during a time of unreliable supplies. The typical procurement process is as follows. The industrial user applies to the fuelwood authority for a certain amount of wood in m3. The authority issues a permit for the industry to harvest a certain block of forest a specific distance from Addis Ababa ranging from 25 km to 600 km away, typically 200 to 300 km. Essentially a fee of 14 to 22 Birr is charged for the privilege of harvesting and the industry must then pay -79- 。，，仁。。、 5 #-t n n c n n t-" n ø» $L (b 0 *Ib l ob M. n ø. M* cr n m. m. 0 ý1% n w flt fA et c"r m I'r rr 5 0 0 ølt r? to pt ffi n CL CL E3 W fA to flt cr to m m to iý n >å* 0 t.ý 190 rr Ilt tå a. n ID m. P. ø tb QQ ID 0 ID rA n ø rr rr æ r. t2 Qh ø rt tz en In rr j~ m. flt tb 0 m » $"b 0* 6 fA rr CO > cr (D ø m. ID ilt 1-4 n øl% V» % $h -4 r. r* n :3 0 ø CD wsr cr cr hJ m C ý3 n ø n v rr er rr ø w W ID & Jei 0 0 t~ (D n fA m m M m 0 a rr el* e'r CL n & i 0 D. tb yr In ID rt rt C4 lø m. 0ý cr ffi ID rf m. CO & & tr r* rt tr Ih :r CD to m. (D to 13 < ID 't to ø (D 9L fA ø. 9 ø t~ CL øh W 0 to %< Ib n w rr øl 0 ø 11 ø r? 1ý pt CO N 0 CD rA ø N> ø. Gi 0 fA f? rt rr - 81 - presented in the Consultant's report which can be obtained from the Energy Department of the World Bank. Summary Tables have been excerpted for the purpose of this Annex). 2.4 The industrial market for agricultural briquette fuels for the Energy I Pilot Project and beyond can be clearly defined by aggregating the data in Tables 2-1 and 2-2. The annual briquette demand can be projected to be from 23,400 tonnes to 32,200 tonnes with 11,000 tonnes needed for Level I applications requiring no modification capital. The next section investigates supplemental industrial customers for the briquettes based on published material, although no visits were made to the sites. Table 2-1 Level 1. No Modifications Needed Industry Location Current Fuel Current Fuel Briquette Substitution Cost of Briquettes (From Addis) (Type & amount (Cost per year USS) (Tonnes per year) (Annual cost USS) a3/4-liters/year) National Alcohol Addis Ababa Fuelcod 193,801 2000 72,100 Dist I lery 5400m3 Ethiopian Hardwood Addis Ababa Fuelwood 19,560 535 19,287 and Softwood Board 1500m3 Plant (ETHARSO) Edget Oil Mill Addis Ababa Fuelwood 49,527 660 23,793 1380m3 Private Brick Addis Ababa Fuelwood 437,696 3625 130,681 Kilnb 80000 + TOTAL * 512,131 Fuel oil 74,435 288,000 Ilter- Tobacco Barns 220 km east of Fuelwood a/ 150,620 1225 119,719 (Awara Melka) Addis Ababa 3440m3 Tobacco Barns 150 km east of Fuelwood 43,059 410 42,131 (Nure Era) Addis Ababa 11503 Lime KiIns 120 km west of Fuel oil 145,000 810 100,570 from Addis Ababa 561,000 liters NeKempte Charcoal 78,262 b/ 61,709 from (525 tonnes est.) Addis Ababa Tobacco Barns 255 km south Fuelwood 141,190 1700 78,387 (Awasa) of Addis Ababa 5000m3 11,000 Total Level I Annual Demand: 11,000 tonnes per year a/ 3440' is demand; actual supply is 860m3 so that leaves rot in f:eld, ;/ Price of charcoal in bulk in Ambo reported by Lime Kiln Plant manager to be $149.07 per tonne. While this seems low, it is used for the analysib. Table 2-2 Level 2. Modifications Required Industry Location Cost of Modification Fuel Oil Displaced Fuel Oil Savings Briquette Substitution Cost of Briquettes (from Addis) (USS) (liters/year) (US$ per year) (tonnes/year) (US$ per year) Cement Plant Addis Abeba A, 135,000 20S - 1.68 million 434,203 4000 144,200 B. 1,000,000 50% - 4.2 militon 1.08 million 10,000 538,800 Ethiopian Hardwood Addis Ababa 100,000 A. 726,000 187,638 1645 59,302 and Softwood Board 100,000 (urrent B. 726,000 liters 187,638 2180 78,589 Plant (ETHARSD rate of consumption) Fuel oil plus 750 207,206 tonnes fuelwood 19,568 100,000 C. 1.4 million 361,836 3170 114,279 Ethiopian Chipwood Addis Ababa 70,000 324,000 83,739 750 27,038 and Furniture Factory Plant (ECAFC0) I Cement Plant Dire Dawa - 380 km 100,000 2% - 1 million 258,460 2270 221,915 a east of Addis Ababa Cement Plant Muger - 100 A, 250,000-400,000 20% - 6.5 million 1.68 million 15,000 1,28 million ke NW of B. 250,000 10% - 3.25 million 840,000 7500 640,000 Addis Ababa C. 135,000 5% - 1.625 million 420,000 3750 320,000 12,400 - 31,200 lotal Level 2 Annual Demand: 12,400-31,200 tonnes per year - 84 - III. Supplemental Industrial Users for Briquette Fuels 3.1 During the length of the mission, it was not possible to investigate each potential user in the appropriate geographical areas. In this section, two additional cases will be dealt with: i) the case of comparing operating costs for briquette fired boilers to electric boiler operating costs, and ii) the case of comparing operating costs for briquette fired boilers to fuel oil fired boilers. 3.2 For the electric boiler case, the assumption is made that all current and future electric boiler users will pay at least the marginal cost for electricity of US$0.03 per kwh for Ethiopia's hydro-based power supply. Assuming a 95% efficiency for electric boilers, a boiler rated at 6 million Btu/hr (6.33 million kJ/hr) output will require an electrical input of 1.85 mw or 1850 kw per hour. The hourly fuel cost for operating the electric boiler at capacity would be $55.50 or $1332 per day for a three-shift operation. For a 300-day working year, the annual charge would be a maximum of $399,600. Assuming a combined use factor of 50%, the annual power cost would be about $200,000. . briquette-fired boiler using briquettes with an 18.6 MJ per kg heat value and operating at 75% overall boiler efficiency would use 454 kg/hr of briquettes, or 11 tonnes per day. At maximum capacity this would be 3300 tonnes for 300 working days, or, at a 50% combined use factor, 1650 tonnes. Using the annual cost of the electricity, i.e. $399,600 minus an 0 and M differential oC $20,000 (4 man years per year of labor + $14,000), and dividing by 3300 tonnes, an equivalent briquette cost of $115.03 is obtained. The obvious conclusion is that if the briquette cost is below $115.03 per tonne delivered, which it will be for almost - 85 - all cases, the cost of operations will be less for briquettes. If the backup boiler to the electric boiler is already wood capable, this is the ideal case where no modification costs will be experienced and the backup role can revert to the electric boiler. If, however, the backup boiler is only fuel oil capable, then a modification cost must be incurred. Using the existing case, a modification could be completed at $70,000. Assuming briquettes were delivered to the plant for $100 per tonne, the simple payback would range from one to two years depending on the combined use factor of the boiler, assuming somewhere between 50% and 100%. At a delivered briquette cost of $80.00 per tonne, the payback falls to between six months and one year, a very attractive situation. This does not consider the economic value of the fuel oil and the resulting foreign exchange savings. In terms of new installations, electric boilers should not be considered, if briquette fuels are available below a delivered cost of $115.03 per tonne. Dual fuel capable (oil and briquettes) installations can be installed to be competitive with an electric boiler installation with tuel oil backup. 3.3 For the fuel oil boiler case, the cost of the fuel oil to the user is assumed as 0.535 Birr per liter or US$0.2585 per liter. Assuming an 82% boiler efficiency for a fuel-oil fired boiler, the boiler rated at six million Btu/hr output (6.33 million kJ/hr) will require a fuel oil input of 193 liters per hour of fuel oil with a heating value of 40.1 MJ/liter. The maximum fuel oil demand is therefore 4632 liters/day at a cost at $1197 per day or 1.39 million liters per year at a cost of $359,100. For a 50% combined use factor this would be 700,000 liters per year at a cost of $180,000. The equivalent briquette cost at rated - 86 - capacity would therefore be $105.79 per tonne assuming 18.6 mJlkg, a 75% boiler efficiency, and an 0 and M differential of $10,000 (2 man years labor per year plus $7,000) a little less attractive than for the electric boiler case. For some cases, however, the delivered briquette cost will be below $105.79 per tonne so that fuel savings will accrue and foreign exchange will be saved. If a modification to use briquettes is required, a delivered cost of $80 per tonne of briquettes results in a 9- 18 month simple payback, and if the delivered cost is $70 per tonne, this drops to 6.5-13 months. The conclusion is that at the delivered costs projected by other World Bank staff and/or consultants, almost all industrial boiler operations found in Ethiopia are both technically and financially viable for consideration of using agricultural briquettes as fuel sources. 3.4 Potential industrial users, not surveyed, where briquette firing might be advantageous are listed in Table 3.1. Taole 3-1 Supplemental industrial Briquette Ptr List Level I Candidates Industry Cur.-a Fuel Current Fuel Briquette Required (type and annual amount) (cost per year) (tonnes per year) United Oil and Fuelwood, 21,000m3 N.A. 7875 Soap Mill (Electric BLR) Akaki Oil Mill Fuelwood, 3300m3 N.A. 1200 150 tonnes fuel oil (Electric BLR) Nazravi Kiba Novg Fuelwood, 2400m3 N.A. 860 Oil Mill Arsina Mirta Fuelwood, 1200m3 N.A. 430 Oil Mill Total Supplemental Annual Level I Briquette Demand: 10,365 tonnes per year Level 2 Candidates Industry Annual Amoun and Cost Modification Cost Annual Briquette Demand of Fuel Oil (S) (5) (tonnes) St, Georges Brewery 1450 tonnes at 180,000 3500 392,850 Aadis Tyre 3000 tonnes at 160,000 7250 813,000 Akaki TextIles 5000 tonnes at 270,000 12,000 1.25 million Modjo Textiles 900 tonnes at 100,000 2200 225,350 Dire Dawa Textiles 7000 tonnes at 360,000 17,000 1.75 million Total Supplemental Annual Level 2 Demand: 41,950 tonnes per year - 88 - IV. Prioritisation of Industrial Applications - Least Cost Solutions 4.1 In order to determine the least cost solutions, both the need for modifications to burn the briquettes and the value of the fuel displaced must be considered. The financial value (cost to user) of the competing fuels is listed in Table 4-1 along with an equivalent delivered briquette cost. 4.2 It is most desirable to have the briquettes used against as many of the conventional fuels as possible during the Energy I Pilot Project. With successful demonstration of briquettes in multiple applications, a widespread implementation can occur without further testing as the briquette production potential is expanded. Table 4-2 presents the priority industrial applications to both take advantage of the best financial situations whila obtaining maximum market type coverage. Table 4-1 Competing Fuel Values Fuel Energy Value Use Efficiency Equivalent Briquette Cost mJ/k2, mJ/Ifter, or mJA/kwh (S) USS/tonne (18.6 aJ/kg at 75% off) Fuelwood (650/tonne) 14.3 65-70 68.46 - 72.26 Fuelwood ($75/tonne) 14.3 65-70 102.69 - 108,39 Fuewood ($100/tonns) 14.3 65-70 136.92 - 144.52 Fuetwood ($125/tonne) 14.3 65-70 171.14 - 180.65 Charcoal (St50/tonne) 29.0 75 96.21 Charcoal ($180/tonne) 29.0 75 115.45 Charcoal (5200/tonne) 29.0 75 128,28 co Charcoal (5250/tonne) 29.0 75 160.34 Fuel Oil (25.85/liter) 40.1 80 113.91 a/ Electricity (3 cts/kwh) 3.6 wJ/kwh 95 115.03 Electricity (6 cts/kwh) 3.5 aJ/kwh 95 230.06 a/ For the special case at the Ambo Lime Kilss that haie a 50% reject rate using fuel oil and a 5-10% reject rate for charcoal (and briquettes assumed), the equivalent price for briquettes is $179.00 per tonne. Table 4-2 Priority Sites for industrial Use of Briquette Fuels industry Fuel Displaced Briquettes Substituted Equivalent Cost Bric.,ttes Delivered Price Cost of Type-Amount-Value (S) (tonnes/year) (/tonne) of Briquettes (S) Modifications National Alcohol Fuetwood-5400M3-193,801 2000 96.90 36.05-71.70 - Distillery Two Private Fuetwood-8000m3- 437,696 3625 141.28 36.05-140.34 - Brick Kilns fuel oil-288,0001- 74,435 512,131 Awara Melka FueIwood-3440mk150,620 a/ 1225 122.96 65.65-113.71 - Tobacco Barns Ambo Lime Kilns Fuel oil-561,0001-145,000 810 179.00 45.71-128.81 - ETHARSO Fuel oil-726,0001- 187,638 2180 95,05 36.05-71.70 100,000 Fuelwood-1500m3 19568% 207,206 United 011 and Fuelwood-25,000m3-N.A. 7875 b/ 115,03 based on 36.05-113,94 - Soap MilII Electricity-40 Gwh-1.2 million electricity use Dire Dawa Fuel-i milliosl-258,460 2270 115.86 77.11-97.76 100,000 Total Briquette Demand for Priority Users: 19,985 tonnes/year 8/ As only 25% of the 3440m3 can be obtained, the analysis underestimates the valhe of the fuelwood, as not being able to purchase causes direct and tangible losses, b/ Not all of the 40 Gwh can be substituted for; full substitution would require 9900-10,000 tonnes. - 91 - 4.3 Two Level 2 cases are included in the priority list. The ETHARSO modification is the easier of the two, with no costly pre- engineering required. All engineering will be routinely done by the retrofit burner supplier based on specifications and drawings of the boiler plus layout drawings of the boiler room. Other information required for control purposes would be average steam rates and the type and duration of boiler load swings caused by process needs. The cement plant modification is a little more complex and should be approached with a specialized cement industry consultant performing the pre-engineering design work and preparing the specification and bid documents to complete the modification. While a formal feasibility study is not required, an exper; should be utilized to design the briquette storage, transfer, grinding and injection system plus interfacing of controls, if desirable. It is recommended that only the 20% potential modification be considered (although all hardware should be designed for 30, possibly 40%) which would pneumatically inject ground-up briquettes into the oil flame zone, and that this be done in the smallest plant, in Dire Dawa. Based on the operations at this plant, optimized designs could be prepared for the Addis Ababa and Muger plant, if desirable and briquette production allows. - 92 - Annex 4 SPECIFICATIONS FOR MAJOR EQUIPMENT Contents I. Site-specific Equipment (a) roffee (i) Workshop and storage equipment (b) Cotton (i) Wheeldrive tractor (ii) Cotton stalk chopper (iii) Self-discharbing forage trailer (iv) Workshop and storage equipment (c) Wheat (i) Wheeldrive tractor (ii) Platbed trailer (iii) Square straw baler (iv) Workshop and storage equipment (d) Maize (i) Wheeldriver trLctor (ii) Single row maize chopper (iii) Self-discharging forage trailer (iv) Baling press for chopped maize (v) Workshop and storage equipment IT. Briquetting Plant Equipment (a) Bale breaker (for wheat and maize residue plants only) (b) Silo (c) Hammermill (d) Screen (e) Piston briquettor (f) Screwpress briquettor (g) Bagging station (h) General requirements (1) Electric motors (ii) Motor controls (iii) Guards 'iv) Manuals (v) Further specifications - 93 - su~iment Spiecification~ for all (4) Screw and Piston Briquetting Plants ZIMMhet dwe. no. 850506, 07, 08. OLpm dwg. no. 850510 and 11 sl dwg. no. 850512, 13, 14 . 13, 15, 16 (correspond with item nos on flow sheeta) Mnit: Piston Briquettor 4 nendd use: to produce fuel briquettes with 75 mm diameter with a density of 1,0 - 1,2 kg/dal am x 500 - 700 kg/h depending on the type of raw mterial Construction: the plant consists of the briquettor with feed hopper comprising a vertical screw with variable speed drive, The housing is made of heavy mild steel plates in welded construction. The motion of the piston is mad. by means of a crank drive with flywheels, flat belt drive and electric motor on tensioning slide rails. the motor has 75 kW. A cooling water system to cool the lubrication oil and the briquettor housing must be supplied with the unit. 10 different dies must be included. An inclined cooling line 12 a long is attached to the die head, height of discharge point 3,5 a above floor level. - 94 - inen Sefication for all (4) Screw and Piston !rique%ting Plants ZIMAhIet 4wg* no. 850506, 07, oe jAvout PUas dwe. no. 850510 and 11 Slo Lan: d*g. no. 850512, 13, 14 us.no 8, 10, 11 (correspond with item nas on flow sheets) gtit: Screw 3riquettor gt 4 Intended uses to produce fuel briquettes with 28 m diameter, with a density of 1,2 - 1,4 kg/da 500 - 700 kg/h depending on the type of raw aterial, the capacity should not be less than 500 kg/h ConstrAtion: the unit consists of the briquet%or with feeding system comprising a small bin with latel indicator to start and stop the discharge screw of the silo, with a vibrating Lhute between the bin and the briquettor inlet. Witth & reduction gear, an elastic coupling and a variable speed AC electric motor ef 75 kW. With a briquettes cutting device and a cooling system for the lubrication oil and the briquettor housing. The briquetces fall into an outlet chute which is suitable to discharge onto a belt conveyor, the chute must be provided with a suctIon hood for the removal of the smoke. The unit must be suppied with 10 die heads and 10 dies with vario4s lengths 95 - 20sontsaec ifi ation, for all (4) Sorew and Piston Briquetting Plants n Sheqet: dwg. no. 850506, 07, 08 dwg. no. 850510 and 11 dwg. no. 850512, 13, 14 . 10, 12, 13, 15, 17, 18 (correspond with item nos on flow sheets) i Baging Station 8 ed uset to hold bags in position suitable ror filling with shovels and to weigh the filled bags each station must hold 2 bags in an upright position leaving full access to the opening of the bag grtuctions the units mnut be mobile on wheels so they can be moved along the cooling heaps. A suitable clamping device must hold the bag during filling. The exchange of bage must be easy. A weighing device met be incorporated in the station. - 96 - Fquitment Stecification Continuation General Requirements Electric Motors All electric motors must be according to the 15C atandard. They must be the squirral cage type T.E..C. (totally enclosed fan cooled). Degzee of protection I? 54 according to IE3. Insulation class 3 accordine to VDE 0530 (German electric standards). They must be suitable :or continuous operation (around the clock). All gear motors to be from Sd. No drum type motors are desired for belt conveyors. otor Controls All motor co-trols must be supplied with the equipment. Motor starters, fuses, push buttons, indicating lamps and relais with spare 1/0's to incorporate some logic interlocks from other plant components must be supplied in a panel. S4.arters for motors with more than 10 k power rating xxtst be of the. star-delta type. Push buttor will generally be installed at sight distance from the corresponding equipment. However the motor controls of some equipment will be incorporated in the L.V. ewitchboard. The motor control components will be standardised as much as possible during the detail planning to facilitate the spares requirement. Guards 3elt dr.ves and other rotating parts must be protected with guards according to DIN 31001 (German General Standards). Sight contact to the rotatine parts should be allowed by using wire mesh surfaces. Mamals The suppliers must provide operating and maintenance manuals, spare part lists and drawings in English after receipt of the order. - 97 - Lst of Equipment which can only be specified at a later stages . Transformer and high voltage switch gear . low voltage switch board (after knowing the exact power ratings of the installed motors) . electric cables and cable trays (after completion. of the final layout plan with the exact dimensions of the equipment which wll be purchased) . general supporting structures, ladders, walkways and platforms for operation and maintenance for the plant. - 98 - Item no.r 21 Unit: Workshop and storage equipment for maintenance of collecting equipment and plant for coffee residue briguetting 1 set of each section QtY. Description Section 1: 1 Bench drilling machine 3 8lectric portable hand drills I Double ended grinding machine 1 Portable grinding machine with accessories. 1 Thread cutting tools 1 Stud removers 1 Measuring tools 3 Vices 1 Kerosine blow lamp Section 2s 1 Arc -ielding machine 1 Oxy-acetyline welding & cutting equipment 1 Tin smith tools 1 Manual shear bench 1 Manual bending machine 1 Long leg vice Section 3: 1 Hydraulic floor crane I Hydraulic jacks -99- Qty. Description 1 angineering measuring instruments 1 axpanding reamers 1 Pullers 2 Maintenance toola in locked boxes 1 Socket wrenches set in locked boxes Section 4: 1 Blactrician tools and equipment Section 6: 1 Storage racks with dravers etc. -100- Specifications of Agricultural Machinery for Cotton Stalk Collection Item t 6 Unit a 2 wheeldrive Tractor Qty. t 7 units Tne a The tractor shall be agricultural rear wheel drive. A test report from a recognized testing centre, preferably in accordance with the O.B.C.D. or Nebraska standard code will be submitted with the tender. gine s Engine shall be of the diesel type-4-stroke cycle- developing about 40 - 45 RN (55-60 HP), at rated speed of about 2000 RPM Cylinders in line with replaceable sleeves. Direct fuel injection. Engine to be suitable for ambient temperatures of up to 45 degrees wCO and dusty conditions. The air cleaner of a heavy duty oil-bath type with precleaner. Bngine to be equipped with a heavy duty water cooling system, large tropical radiator, centrifugal pump and large fan. The lubrication system must be forced feed, equipped with gear type pump and oil strainer in sump. The fuel filters to be of dual stage system with replaceable elements. Blectrical System: To be 12 V, precharged battery of about 85 A, starter motor and alternator. An ample lighting system has to include 2 headlights, sidelights, tail and plough lights. Standard instrument panel equipped with hour meter, engine speed, temperature, oil pressure, fuel meter, light indicators, etc. - 101 - Transmissions Dry type dual clutch with a largest possible diameter however not less than 11 inches. multipower or powershift transmission with 12-16 forward and 4-8 reverse speed. Hydraulics: Three-point linkage cat. II with adjustable lift arms live draught and position control. Minimum lift capacity 1,800 kg. at the end linkage, swinging drawbar. Track & Wheels: Wheeltracks must be adjustable between 1.60 and 1.80 mtre. Tractors to be equipped with regular agricul- tural tyres of natural rubber and innertubes. the following approx. tyre sizes are required. Front : 6.50 x 16- 6 PR Rear t 12.4 z 28- 8 PR Brakes: Foot operated differential lock with automatic disenjagement devide. Multiple plate oil cooled brakes and parking brake. Power take off: An independent PTO with 6 splines 35mm (1.38 inch) speed 540 rpm. Steerings Power steering. Miscellaneouss Fally cushioned seat with height adjustment, overhead safety guard with sunshade. - 102 - Toolo. special equipment and accessoires: Set of tools, to be included With each machine, also fire extinguisher, grease gun, and hydraulic jack. Special tools, equipment and accessoires should be offered. others i Operators manual, parts catalogue, workshop manual for each unit in English to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare-garts: A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item to a total not exceeding 20% of C & F value of units. - 103 - Item Mo a 7 Unit t Cotton stalk chopper Quantity 5 units Ie a PTO driven mounted on small trailer Capacitys 5 tons chopped material per hour Description t The unit will be used to chop cotton stalks with diameters of up to 0.04 mtra. and length up to 1.70 mtrs. The stalks will be cut manually and fed to the chopper by hand from a swath 3.60-5.40 mtrs. Moisture content of the' stalks at time of chopping will not exceed 15% (MCIB) and stalk production will reach about 3800 KgstBA. The chopper will be connected to the wheeltractor of para. I and is driven via the P.T.O. shaft of that tractor. The unit is provided with a drawbar hook,to pull the forage trailer of para. 3 during chopping operations. The chopper has to cut the stalks in chips having dimensions not exceeding 15x10x5 mm. The capacity of the unit at maximum chip length should not be less than 2.5 tons/hr. Bxecution a The unit has to be provided with: - Adjustable number of wear resistant knives, up to 12 pea. to adjust chip dimensions. - alower of sufficient capacity to blow the chopped material into the forage trailer. - Blower discharge chute should he adjustable from the drivers seat. - Shearbolts and/or safety pins/systems to ensure a safe operation of the unit. - 104 - Others$ Operators manual, parts catalague, workshop manual for each unit to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare Parts s A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item not exceeding 20 per cent of C G F value of units. - 105 - Item S 8 Unit a Self discharging forage trailers. Quantity 7 units Tye! a PTO driven unloading system. Capacitys 25 m chopped cotton residue with a weight of about 4 tons. Frame s Rigid construetion, hot rolled steel. Description a The unit will be used to receive chopped material from the chopper of para.2, to transport this to the plant and to discharge it by means of a built in conveyor system. The trailer will be connected to the a.m. chopper during loading operations and directly to the wheeltractor of para.1 during transport and unloading operations. The trailer of the tandem axle type having a wheeltrack of 1.80 mtres. should be freestanding (to facilitate connection and disconnection to chopper and tractor) and designed for a total carrying capacity of 4 tons and a net volume of about 25 a3, having a total height not exceeding 3.25 mtre. Unloading will be arranged by means of a moving floor and cross conveyor discharging the material siCjways at either the front or rear end of the trailer. Discharge operations and rates are to be controlled from the tractor driver's seat. The unloading system may be driven by means of the hydraulic system or the P.T.0. drive of the tractor. the trailer, of all steel construction consisting of hot rolled channel steel chassis and frame members is provided with heavy duty bottom chains with detacheable transport books. - 106 - All walls of the forage box are to be of the closed# reinforced type, with either front or rear wall, depending on the discharge system, opening and closing from the drivers seat. All provisions to prevent loss of chopped material are to be included in the design. The unit is furthermore provided with: - Suitable drawbar with shockabsorber device and turnable draveye. R Rear pulling hook for rescue operations. - Pront and rear reflectors. Radial tyres of not less than 11.5 x 15 - 8 PR. - The required hydraulic hoses, pump, P.T.O. shaft etc. for connection to the tractor. - Overrun expanding brakes coming into operation when the tractor brakes are applied. - Having duty square shaped high tensile steel axles of not less than 55 mm. Others Operators manual, parts catalogue, workshop manual for each unit to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare parts: A cumprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item not exceeding 20 of C a P vali!e of units. - 107 - Item no.: 10 Units Workshop and storage equipment for maintenance of collecting equipment and plant for cotton stalk briguetting 1 set of each section Qty. Description Section 1: 1 Bench drilling machine 3 Blectric portable hand drills 1 Double ended grinding machine 1 Portable grinding machine with accessories. 1 Thread cutting tools 1 Stud removers 1 Measuring tools 1 Power hack saw 1 Hydraulic floor press 3 Vices 1 Kerosine blow lamp Section 2: 1 Engine driven Arc welder 1 Oxy-acetyline welding & cutting equipment 1 Tin smith tools 1 Manual shear bench 1 Manual bending machine 1 Long leg vice - 108 - Qty. Description Section 3: 1 Engine stand 1 Hydraulic floor crane 1 Hydraulic trolly Jacks 1 Hydraulic jacks 1 Piston and ring service equipment 1 Cylinder head.service equipment 1 Injector tester with injector service equipment 1 Valve and seat grinder 1 angineering measuring instruments 1 Expanding reamers 1 Pullers 1 Torque wrencha 2 Maintenance tools in locked boxes 1 Socket wrenches set in locked boxes Section 4: 1 Heavy duty battery charger 1 Electrician tools and equipment Section 5: 1 Air compressor with accessoires 1 Vulcanising unit Section 6s I Storage racks with drawers etc. - 109 - Specifications of Agricultural machinery for Straw Collection Item No. 1 Unit s 2 wheeldrive tractor QtY. : 5 units Ty1w i The tractor shall be agricultural rear wheel drive tractor. A test report from a recognized testing centre preferably in accordance with the O.B.C.D. or Nebraska standard code will be submitted with the tender. Engine s Engine shall be of the diesel type- 4-stroke cycle- developing about 40 - 45 RN (55-60 HP), at rated speed of about 2000 RPM. Cylinders in line with replaceable sleeves. Direct fuel injection. Engine to be suitable for ambiert temperatures of up to 45 degrees C and dusty conditions. The air cleaner of a heavy duty oil-bath type with precleaner. Engine to be equipped with a heavy duty water cooling system, large tropical radiator, centrifugal pump and large fan. The lubrication system must be forced fed, equipped with gear type pump and oil strainer in sump. The fuel filters to be of dual stage system with replaceable elements. Electrical System: To be 12 V, precharged battery of about 65 AB, starter motor and alternator. An ample lighting system has to include 2 headlights, sidelights, tail and plough lights. Standard instrument panel equipped with hour meter, engine speed, teMperature, oil pressure, fuel meter, light indicators, etc. * 110 - Transmission: Dry type dual clutch with a largest possible diameter however not less than 11 inches. Multipower or powershift transmission with 12-16 forward and 4-8 reverse speed. Hydraulics: Three-point linkage cat. 11 with adjustable lift arms, live draught and position control. Minimum lift capacity 1,800 kg. at the end linkage, swinging drawbar. Track & Wheels% 'theeltracks must be adjustable between 1.60 and 1.80 mtrs. Nractors to be equipped with regular agricul- tural tyres of natural rubber and innertubes. The following approx. tyre sizes are required: Front : 6.50 x 16 - 6 PR Rear t 12.4 x 28- 8 PR Brakes: Foot operated differential lock with automatic disengagement device. Multiple plate oil cooled brakes and parking brake. Power take off: An independent PTO with 6 splines 35mm (1.38 inch), speed 540 rpm. Steering: Power steering. Miscellaneous: Fully cushioned seat with height adjustment, overhead safety guard with sunshade. - 111 - Tools, special equipment and accessoiress Set of tools, to be included with each machine, also fire extinguisher, grease gun, and hydraulic Jack. Special tools, equipment and accessoires should be offered. Others s Operators manual, parts catalogue, workshop manual for each unit in English to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare parts: A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted seiarately for each item to a total not exceeding 20% of C a F value of units. - 112 - Item a 2 Unit a Flat bed trailer Quantitys 4 units a 4 wheels, 2 axle, turntable, carrying capacity S tons. Size t Platform 2.50 x 7.25 mtrs. Frame a Rigid construction, hot rolled steel. The unit is provided with: suitable drawbar with shockabsorber device and turnable draveye - Rear pul'ing hook for rescue operations - Front anj rear reflectors - Radial tyres of not less than 12.5 x 15 - 8 PR - Overrun expanding brakes coming into operation when the tractor brakes are applied Heavy duty, square shaped, high tensile steel axles of not less than 55 mm. Note: Please observe that axle springs and a lighting system are not required. Others: Parts catalogue and workshop manual for each unit to be received after ordering. Pamphlets to be sent with the offer and also country of origin has to be stated. Spare parts: A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item not exceeding 20%, of C & F value of units. - 113 - Item t 3 Unit t Square straw baler Quantity s 3 TyRe t suitable to produce square bales with size of aprox. 0.35 x 0.45 x 0.85 - 1.15 metre Description t The unit will be used to bale wheat straw laying in swaths after harvesting of the crop by combine harvesters. The swaths (covering a harvested area of about 5.00 mtrs. wide) are about 1.20 mtrs. wide and the recoverable straw production is estimated at 2,100 kgs/BA at a moisture content of less than 15 per cent at time of baling. The baler will be operated by the P.T.O. drive of the tractor as described in parea 11*. The gathering width of the unit should not be less than 1.50 mtrs., with tine spacing of the pick-up device not exceeding 70 mm. Number of ram strokes between 75 and 100 per minute at 540 R.P.M. of the P.T.O. shaft. Executions The unit has to be equipped with: - Double twine system, with direct driven knotters; - Twine box; - Drawbar and P.T.0. shaft for connection to the tractor; - Trailer hitch; - Flywheel of suitable dimensions to even out power surges; - Adjustable pick-up heihgt to be controlled from the operators seat; - Sale density adjusters; - Power overrun device by slip-clutch or similar; - Tyres at pick-up side of not less than 7.00 x 12 -6 PR and balecase side of not less than 10.00 x 15 - 6 PR. - 114 - The delivery should include sufficient baler twine to produce in total 360,000 bales with an average length of 1.00 mtr. Others t Operators manual, parts catalogue, workshop manual for each unit to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare Parts : A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item not exceeding 20 per cent of C & F value of units. - 115 - Item no.s 5 Unit S Workshop and storage equipment for maintenance of collecting equipment and plant for straw briguetting Quantityt 1 set of each section QtY. Description Section Is 1 Bench drilling machine 3 Blectric portable hand drills 1 Double ended grinding machine 1 Portable grinding machine with accessories. 1 Thread cutting tools 1 Stud removers 1 Reasuring tools 1 Power back saw 1 Hydraulic floor press 3 Vices 1 Kerosine blow lamp Section 2: 1 angine driven Arc welder 1 Oxy-acetyline welding a cutting equipment 1 Tin arith tools 1 Manual shear bench 1 Manual bending machine 1 Long leg vice - 116 - 2ty. Description Section 3: 1 Engine stand 1 Hydraulic floor crane 1 Hydraulic trolly Jacks 1 Hydraulic jacks 1 Piston and ring service equipment 1 Cylinder head service equipment 1 Injector tester with injector service equipment 1 Valve and seat grinder 1 Engineering measuring instruments 1 Expanding reamers 1 Pullers 1 Torque wrenche 2 Maintenance tools in locked boxes 1 Socket wrenches set in locked boxes Section 4s 1 Heavy duty battery charger 1 Electrician tools and equipment Section 5S 1 Air compressor with accessoires 1 Vulcanising unit Section 6: storing equipment 1 Storage racks with drawers etc. - 117 - Specifications of Agricultural Machinery for Raise Residue item Not 11 Unit a 2 wheeldrive Tractor QtY. a 8 units TXe e The tractor shall be agricultural rear wheel drive. A test report from a recognized testing centre preferably in accordance with the O.E.C.D. or Nebraska standard code will be submitted with the tender. Engine a Engine shall be of the diesel 4-stroke cycle developing about 40 - 45 RN (55-60 UP), at rated speed of about 2000 RPM. Cylinders in line with replaceable sleeves. Direct fuel injection. Engine to be suitable for ambient temperatures of up to 45 degrees C and dusty conditions. - The air cleaner of a heavy duty oil-bath type with precleaner. Engine to be equipped with a heavy duty water cooling system, large tropical radiator, centrifugal pump and large fan. The lubrication system must be forced feed, equipped with gear type pump and oil strainer in sump. The fuel filters to be of dual stage system with replaceable elements. Electrical Systems To be 12 V# precharged battery of about 85 AB, starter motor and alternator. An ample lighting system has to include 2 headlights, sidelights, tail and plough lights. Standard instrument panel equipped with hour meter, engine speed, temperature, oil pressure, fuel meter, light indicators, etc. - 118 - Transmissions Dry type dual clutch with a largest possible diameter however not less than 11 inches. Multipower or powershift transmission with 12-16 forward and 4-S reverse speed. Bydraulicss Three-point linkage cat. II with adjustable lift arms, live draught and position control. Minimu lift capacity 1,800 kg. at the end linkage, swinging drawbar. Track & Wheels: Wheeltracks must be adjustable between 1.60 and 1.80 mtrs. Tractors to be equipped with regular agricul- tural tyres of natural rubber and innertubes. The following approx. tyre sixes are required. Front : 6.50 x 16- 6 PR Rear s 12.4 x 28- 8 PR Brakess root operated differential lock with automatic disengagement device. Multiple plate oil cooled brakes and parking brake. Power take ofts An independent PTO with 6 splines 35mm (1.38 inch), speed 540 rpm. Steering: Power steering. * 119 - Miscellaneoust Fully cushioned seat with height adjustment, overhead safety guard with sunshade. Tools. special equipment and accessoires: Set of tools to be included with each machine# also fire extinguisher, grease gun, and hydraulic jack. Special tools, equipment and accessoires should be offered. Others a Operators manual, parts catalogue, workshop manual for each unit in Bnglish to be received after ordering. Pamphlets to be sent with the offer and country ef origin has to be stated. Spare parts: A comprehensive list of fast and slow moving spare parts recommended for two years most accompany the tender. Prices should be quoted separately for each item to a total not exceeding 20% of C a F value of units. - 120 - Item v 12 units Single Row Maize chopper Quantity 5 units XXpe a PTO driven Capacitys 4 tons chopped material per hour Description t The unit will be used to recover the maize stalks that are left in the field after the cobs have been picked by hand. The chopper may be supplied from a swath with stalks already cut by hand or will be used to cut and chop one single row of stalks at a time. Moisture content of the stalks at time of chopping will be less than 20% (RCNB) and stalk production will reach to about 3000 kgs./BA. The chopper will be connected to the 3 point linkage of the N wheeltractor of para.1. and driven by the P.T.0. The unit is provided with a drawbar book to pull the forage trailer of para. 3 during chopping operations. The chopper has to cut the stalks in lenghts adjustable betwean 25-30 mm. and 70-75 am. by either changing the number of knives and/or changing the knife-speed. Bxecution : . The unit is equipped withs - Adjustable number of wear resistant knives, up to 12 pcs. to control chip length - Blower of sufficient capacity to blow the chopped material into the forage trailer. - Slower discharge chute should be adjustable from the drivers seat. - 121 - - A dual purpose gearbox to allow the operation of either the chopper or the discharge of the trailer without disconnecting one of the units. - Shearbolts and/or safety pins/systems to ensure a safe operation of the unit. Otherst Operators manual, parts catalogue, workshop mannual for each unit to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare parts: A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item in total not exceeding 20%, of C & P value of units. - 122 Item NO s 13 Unit i Self discharging forage trailers. Quantity 8 units Type s PTO driven unloading system. Capicitys 25 a3 chopped maize residue with a weight of about 4 tons. Prana a Rigid construction, hot rolled steel. Description a The unit will be used to receive chopped material from the chopper of para.2* to transport this to the plant and to discharge it by means of a built in conveyor system. The trailer will be connected to the a.m. chopper during loading operations and directly to the wheeltractor of para.1 during transport and unloading operations. The trailer of the tandem axle type having a wheeltrack of 1.80 mtre. should be freestanding (to facilitate connection and disconnection to chopper and tractor) and designed for a total carrying capacity of 4 tons and a net volume of about 25 a3, having a total height not exceeding 3.25 tre. Unloading will be arranged by means of a moving floor and cross conveyor discharging the material sideways at either the front or rear end of the trailer. Discharge operations and rates are to be controlled from the tractor driver's seat. The unloading system may be*driven by hydraulic system or the P.T.0. drive of the tractor. - 123 - The trailer of all steel construction consisting of hot rolled channel steel chassis and frame members are provided with heavy duty bottom chains with detacheable transport hooks. All walls of the forage box are to be of the closed reinforced type# whereas either front or rearvall, depending on the discharge system, opening or closing from the drivers seat. All provisions to prevent loss of chopped material are to be included in the design. The unit is provided with: - Suitable drawbar with shockabsorber device and turnable draweye. - Rear polling hook for rescue operations. Front and rear reflectors. - Radial tyres of not less than 11.5 x 15 - 8 PR. - The required hydraulic hoses, pump, P.T.O. shaft etc. for connection to the tractor. - Overrun expanding brakes coming into operation when the tractor brakes are applied. Having duty square shaped high tensile steel axles of, not less than 55 am. Others: Operators manual, parts catalogue, workshop manual for each unit to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare of parts: A comprehensive list of fast and slow moving spare parts recommended for two Tears must accompany the tender. Prices should be quoted separately for each item not exceeding 20% of C G F value of units. - 124 - Item no.s 15 Units Baling press for chopped maize stalks QtYS 2 units Type: Fully automatic self binding. Capacity: 2500 kg material per hour or 125 bales per hour chopped maize stalks with a bulk density of 160 kg/cha. Dimensions of bales: About 50 cm width, 40 cm height and a length of 80 to 120 cm variable. Weight per bale: 20 - 25 kilos at a bulk density of 180 - 350 kg/ch. Bindings Preferable with plastic or sisal rope. Description: The unit will be used to press chopped maize stalks to bales. The material will be fed into a chopper after which it will be pressed fully automatic. The bales leave the machine double twined. The delivery should include sufficient baling rope to produce in total 250.000 bales with an average length of 1,00 metre. - 125 - Tools, special equipment and accessoires: Set of tools, to be included with each machines* such as, grease gun etc. Special tools, equipment and accessoires should be offered. Others: Operators manual, parts catalogue, workshop manual for each unit in English to be received after ordering. Pamphlets to be sent with the offer and country of origin has to be stated. Spare parts: A comprehensive list of fast and slow moving spare parts recommended for two years must accompany the tender. Prices should be quoted separately for each item not exceeding 20% of C & F value of units. - 126 - Item no.: 18 Unit: Workshop and storage equiment for maintenance of collecting equipment and plant for maize residue briguetting 1 set of each section QtY. Description Section 1: 1 Bench drilling machine 3 Electric portable hand drills 1 Double end grinding machine 1 Portable grinding machine with accessories. 1 Thread cutting tools 1 Stud removers 1 Measuring tools 1 Power hack saw 1 Hydraulic floor press 3 Vices 1 Kerosine blow lamp Section 2: 1 Engine driven Arc welder 1 Oxy-acetyline welding & cutting equipment 1 Tin sith tools 1 Manual shear bench 1 Manual bending machine 1 Long leg vice - 127 - Qty. Description Section 3: 1 Engine stand 1 Hydraulic floor crane 1 Hydraulic trolly Jacks 1 Hydraulic jacks 1 Piston and ring service equipment 1 Cylinder head service equipment 1 Injector tester with injector service equipment 1 Valve and seat grinder 1 Engineering measuring instruments 1 Expanding reamers 1 Pullers 1 Torque wrenchs 2 Maintenance tools in locked boxes 1 Socket wrenches set in locked boxes Section 4: 1 Heavy duty battery charger 1 Electrician tools and equipment Section 5: 1 Air compressor with accessoires 1 Vulcanising unit section 6s 1 Storage racks with drawers etc. - 128 - bquirment Specification Plant: Maise Stalks and Wheat Straw Screw and Piston Briquetting Flow Sheeta dwg. no. 850507 Plot Plan S dwg. no. 850513 Item no. 2 (corresponds with item no on flow sheet) Unit: Bale Breaker LU s 2 Intended use: To break bales made of chopped maize stalks and wheat straw. The bales are fed by means of an inclined belt conveyor. Strings are removed by hand before the bales are fed onto the belt conveyor. CaLacity : up to 2000 kg/h of bales, size 0,4 x 0,5 x 0,85 - 1,15 ., weight of each bale up to 25 kg, i.e. up to 80 bales per hour Construction: drum type rotor with exchangeable teeth, rotor shaft to be supported with grease lubricated spherical roller bearings, housing made of welded mild steel plates. With enclosed inlet chute preferably leading bales with a 45 degree angle into the bale breaker. The inlet chute must be provided with a by-pass to feed loose cotton stalks directly onto the discharging conveyor. With auction hood for dust removal. With flywheel and v-belt drive, with electric motor. Access for maintanance must be easy. The unit must be supplied with 3 sets of teeth. The machine must be provided with a vibration sensor to signal unblanced rotor due to uneven wear on teeth. - 129 - a efor all (4) Screw and Piston friquettiag Plants ow Set dwe. no. 850506, 07, 08 e Las dwS. no. 850510 and 11 Plot Plans dwg. no. 850512, 13, 14 t . 7, 9, 10 (oorrespond with item nos an flow sheets) %its Silo Ms 4 Intended uses Intermediate puffer store for dried residue, ready for briquetting, to even out fluctuations in the mmterial flow and to nke the operation of the briquettor more iadependant from the other plant sections CaVeitr storage capacity approx 6 a3, discharge papacity up to 750 kg/h for each discharge screw, up to a m um of 4 independant discharge bares. Construotions mild steel metal sheet housing with structual steel supports down to the floor level. Right of discharge port 2,8 a above floor level. At the beginning the silo will only be equipped with one discharge screw, with fixed speed electric drive for the screw. The floor of the silo must be prepared to receive up to 3 additional screw conveyors at a later stage. The interior of the silo must be provided with a rotating agitator to distribute the material even over the discharge screws. High and low level sensors must be included, preferable of the rotary type. The silo must be equipped with an access ladder and a man hole in the cover plate. - 130 - Specification a for all (4) Screw and Piston Briquetting Plants t dvg. no. 850506, 07, 08 u a g. no. 850510 and 11 s dwg. no. 850512, 13, 14 'vo. 2, 4, 5, (correspond with item nos on flow sheets) I Hammer Mill Bs 4 itended uset to reduce the sise of the residues without producing excessive dust. The milled fraction is removed by means of pnevatic conveyors and some of the conveying air can be sucked through the mills. Capacityt Residues kgh I coffee husks 2500 250 - 350 chopped cotton stalks 2000 100 - 120 chopped maise stalks 2000 80 - 100 wheat straw 2000 60 - 80 Construction: rotor with free swinging hammers supported in grease lubricated spherical roller bearings, housing made of welded mild dteel plates, discharge closed with perforated screens, access to hammers and screens must be easy for main- tenance and for exchanging, with enclosed inlet chute suitable for feeding with belt conveyor, with a auction funnel at the bottom to be connected to a pneumatic conveying pipe, with 5 sets of hammers and 5 sets of screens with different perforations. The hamer mill must be provided with a vibration sensor to signal if the rotor unbalanced due to uneven wear on hammers. - 131 - Ainent Speciftoation for all (4) Screw and Piston Briquetting Plants Flow Sheet: dwg. no. 850506, 07, 08 layout Plan: dug. no. 850510 and 11 plot Plans dwg, no. 850512, 13, 14 U B 4, 6, 7, (correspond with item nos on flow sheets) Wts Three Deck Screen Ms 4 Intended uses to divide the residues into three fractionst Praction lt Overflow of first screen and third screen for piston briquettor Fraction 2s Overflow of second screen for screw briquettor fraction 3: which passes through all three screens for disposal Constructions preferably slow motion type screen with crank drive over a v-belt drive for easy adjustment as required. With stainless steel wire .screens tensioned in an enclosed mild steel frame. Maintenace and changing of screens must be easy. Eaoh unit must be supplied with ten sets of screens with various mesh sies, with square holes ranging from 1 to 8 sm. Casoitys see pnentic conveyors items 3, 5, 6 - 132 - Annex 5 LIST OF RECOMMENDED EQUIPMENT SUPPLIERS FOR BRIQUETTING PLANTS 1. Bale breakers and hammermills (a) Patman KG, D-666 Zweibrucken, W. Germany (b) Condux-Werk, D-6451 Wolfgang, W. Germany (c) Buehler Brothers, CH-9240 Uzwil, Switzerland 2. Silos (a) Weiss Brithers KG, D-6343 Frohnhausen, W. Germany 3. Screens (a) Aligaier-Werke GmbH, D-7336 Uhingen, W. Germany (b) The Orville Simpson Company, Cincinati, Ohio 45223, USA 4. Piston Briquettors (a) Rosenmund AC (Hausmann presses), CH-4410 Liestal, Switzerland (b) Gebr. Hofmann, D-8701 Eibelstadt, W. Germany (c) J. Mared AB, Huskvarna, Sweden 5. Screw Briquettor (a) Biomass Development Europe SA, B-1040 Bruxelles, Belgium - 133 - 6. Belt conveyors (a) REFO AG, CH-4222 Zwingen, Switzerland (b) Jost Brothers AG, CH-3527 Heimberg, Switzerland 7. Pneumatic Conveyors (a) Keller Lufttechnik GmbH, D-7312 Kirchheim, W. Germany or Keller & Co., CH-8105 Regensdorf, Switzerland (b) Ventilator Staefa AG, CH-8712 Staefa, Switzerland - 134 - AMME 6 SUPERVISING 8GIMER: TERMS OF E Scope of Work 1. A supervising engineer will be hired to facilitate the implementation of all pilot plants and to initiate a technical monitoring and evaluation program over a period of three crop seasons. The engineer will have several sets of responsibilities which will occur during (1) the detailed planning phase, (2) training and construction, (3) installation and commissioning, (4) the start-up period, and (5) over three crop seasons of plant operation. In addition, the supervising engineer will play a monitoring role for the World Bank throughout the project. The component tasks for each of these responsibilities are listed below. Terms of Reference 2. During the design and tendering phases, the engineer will be responsible for: (a) reviewing all designs, tender documents, and equipment specifications to ensure acceptability and compatibility; (b) travelling overseas to inspect major equipment components at their manufacturing site prior to shipment to Ethiopia; (c) after seafreight but before local transport, checking the condition of crates and of uncrated major equipment to see if the consignment is complete and intact according to the packing list; - 135 - (d) checking the condition of crates and equipment after arrival at the site and making sure that the shipment is complete according to the packing list; (e) in the case of damaged crates and equipment, ensuring that claims are filed with the appropriate insurance company; (f) coordinating between equipment suppliers to ensure proper interface of plant components; (g) checking equipment design with regard to ease of maintenance and operation within Ethiopia; (h) reviewing maintenance and operating instructions to ensure that they are applicable specifically to the equipment supplied, and incorporating all individual instructions into one common manual; (i) studying spare part proposals to make suggestions for standardization in order to limit the need for specialized spares; and (j) reporting periodically to the World Bank, especially if a Bank intervention is anticipated. 3. During the training and construction period, the engineer will undertake the following: (a) designing, reviewing and coordinating training programs for skilled local labor in conjunction with equipment suppliers; (b) supervising, whenever possible, the installation and assembly of key equipment; (c) regarding site construction, making at least two check-ups during the execution phase and one final check-up after - 136 - completion to compare the size of buildings, foundations and site works for power supply to see if they are in accordance with drawings, specifications and instructions; and (d) reporting regularly to the World Bank, especially if a Bank intervention is anticipated. 4. During installation and commissioning, the engineer will be responsible for the following tasks: (a) checking the proper execution of equipment erection, installation, test runs and commissioning; (b) ensuring that future operators and maintenance staff assist overseas erection personnel during erection and installation; (c) preparing standardized fault protocols for the performance reports during the breaking-in period and the first year of production; (d) instructing the operating and maintenance staff on how to fill in the protocols; and (e) reporting periodically to the World Bank, especially if a Bank intervention is anticipated. 5. During the breaking-in period, the supervising engineer will undertake the following assignments: (a) making sure that fault protocols are properly completed by staff; (b) assisting the operating staff in solving operational problems and the maintenance staff in conducting repairs; (c) informing equipment suppliers about recorded faults and deficiencies to get their advice and assistance; and - 137 - (4) reporting periodically to the World Bank, especially if a Bank intervention is anticipated. 6. During the three crop season production period, the engineer will be responsible for the following activities: (a) visiting each plant periodically to make sure that the operating and maintenance staff continue to record deficiencies in the fault protocols; (b) informing equipment suppliers about the recorded deficiencies to get their advice; (c) assisting *the operating staff with problem-solving and implementing the advice of equipment suppliers; (d) ensuring that production rates are properly recorded; (e) connducting quality control exercises; and (f) reporting periodically to the World Bank, especially if an intervention is anticipated. 7. In addition, the engineer will conduct a series of checks whenever equipment is procured. Specifically, these includet (a) After seafreight but before local transport, checking the condition of crates aud of uncrated major equipment to see if the consignment is complete and intact according to the packing list; 8. After arrival at the site, checking the condition of crates and equipment, and making sure that the shipment is complete according to the packing list; (a) Regarding site construction, making at least two check-ups during the execution phase and one final check-up after - 138 - completion to compare the sise of buildings, foundations and site works for power supply to see if they are in accordance with drawings, specifications and instructions; and (b) in the case of damaged crates and equipment, ensuring that all matters are reported to and followed up by the appropriate insurance company. ENERGY SECTOR MNA-GEMENT ASSISTANCE PROGRAMN Activities Completed Date Completed Energy Assessment Status Report Papua New Guinea July, 1983 Mauritius October, 1983 Sri Lanka January, 1984 Malawi January, 1984 Burundi Pebruary, 1984 Bangladesh April, 1984 Kenya May, 1984 Rwanda May, 1984 Zimbabwe August, 1984 Uganda August, 1984 Indonesia -September, 1984 Senegal October, 1984 Sudan November, 1984 Nepal January, 1985 Zambia August, 1985 Peru August, 1985 Haiti August, 1985 Paraguay September, 1985 Morocco January, 1986 Niger February, 1986 Project Formulation and Justification Panama Power Loss Reduction Study June, 1983 Zimbabwe Power Loss Reduction Study June, 1983 Sri Lanka Power Loss Reduction Study July, 1983 Malawi Technical Assistance to Improve the Efficiency of Fuetwood Use in Tobacco Industry November, 1983 Kenya Power Loss Reduction Study March, 1984 Sudan Power Loss Reduction Study June, 1984 Seychelles Power Loss Reduction Study August, 1984 The Gambia Solar Water Heating Retrofit Project February, 1985 Bangladesh Power System Efficiency Study February, 1985 The Gambia Solar Photovoltaic Applications March, 1985 Senegal Industrial Energy Conservation June, 1985 Burundi Improved Charcoal Cookstove Strategy September, 1985 Thailand Rural Energy Issues and Options September, 1985 Ethiopia Power Sector Efficiency Study October, 1985 Burundi Peat Utilization Project November, 1985 Botswana Pump Electrification Prefeasibility Study January, 1986 Uganda Energy Efficiency in Tobacco Curing Industry February, 1986 Indonesia Power Generation Efficiency Study February, 1986 Uganda Fuelvood/Forestry Feasibility Study March, 1986 Date Completed Project Formulation and Justification (cont.) Sri Lanka Industrial Energy Conservation- Feasibility Study March, 1986 Togo Wood Recovery in the Nangbeto Lake April, 1986 Rwanda Improved Charcoal Cookstove Strategy August, 1986 Institutional and Policy Support Sudan Management Assistance to the Ministry of Energy & Mining May, 1983 Burundi Petroleum Supply Management Study December, 1983 Papua New Proposals for Strengthening the Guinea Department of Minerals and Energy October, 1984 Papua New Guinea Power Tariff Study October, 1984 Costa Rica Recommended Tech. Aset. Projects November, 1984 Uganda Institutional Strengthening in the Energy Sector January, 1985 Guinea- Recommended Technical Assistance Bissau Projects April, 1985 Zimbabwe Power Sector Management April, 1985 The Gambia Petroleum Supply Management Assistance April, 1985 Burundi Presentation of Energy Projects for the Fourth Five Year Plan May, 1985 Liberia Recommended Technical Assistance Proj. June, 1985 Burkina Technical Assistance Program March, 1986 Senegal Assistance Given for Preparation of Documents for Energy Sector Donors' Meeting April, 1986 Zambia Energy Sector Institutional Review November, 1986 Jamaica Petroleum Procurement, Refining & Dist. November 1986