Gayathri Bio Fuels

CONTENTS

Sl.No PARTICULARS PAGE NO

1. Industry Profile 2 - 10

2. Company Profile 11 – 14

3. Organizational Structure 15 – 27

4. SWOT Analysis 28 – 32

5. Findings, Suggestions and Conclusion 33 - 36

6. Bibilography 65- 66

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INDUSTRY PROFILE

A briquette (or briquette) is a block of flammable matter used as fuel to start and maintain fire. Common types of briquettes are charcoal briquettes and biomass briquettes.

Constituents of charcoal briquettes

Wood charcoal (fuel)

Mineral char (fuel) Mineral carbon (fuel)

Limestone (ash colorant)

Starch (binder)

Borax (release agent)

Sodium nitrate (accelerant)

Sawdust

Wax (some brands: binder, accelerant, ignition facilitator).

Chaff (Rice chaff and peanut chaff)

Some briquettes are compressed and dried brown coal extruded into hard blocks. This is a common technique for low rank coals. They are typically dried to 12-18% moisture, and are primarily used in household and industry.

Peat briquettes

In Ireland, peat briquettes are a common type of solid fuel, largely replacing sods of raw peat as a domestic fuel. These briquettes consist of shredded peat, compressed to form a virtually smokeless, slow-burning, easily stored and transported fuel. Although often used as the sole fuel for a fire, they are also used to quickly and easily light a coal fire.

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Biomass briquettes

Biomass briquettes are made from agricultural waste and are a replacement for fossil fuels such as oil or coal, and can be used to heat boilers in manufacturing plants, and also have applications in developing countries. Biomass briquettes are a renewable source of energy and avoid adding fossil carbon to the atmosphere.

A number of companies in India have switched from furnace oil to biomass briquettes to save costs on boiler fuels. The use of biomass briquettes is predominant in the southern parts of India, where coal and furnace oil are being replaced by biomass briquettes. A number of units in Maharashtra (India) are also using biomass briquettes as boiler fuel. Use of biomass briquettes can earn Carbon Credits for reducing emissions in the atmosphere. Lanxess India and a few other large companies are supposedly using biomass briquettes for earning Carbon Credits by switching their boiler fuel. Biomass briquettes also provide more calorific value/kg and save around 30-40 percent of boiler fuel costs.

A popular biomass briquette emerging in developed countries takes a waste produce such as sawdust, compresses it and then extrudes it to make a reconsistuted log that can replace firewood. It is a similar process to forming a wood pellet but on a larger scale. There are no binders involved in this process. The natural lignin in the wood binds the particles of wood together to form a solid. Burning a wood briquette is far more efficient than burning firewood. Moisture content of a briquette can be as low as 4%, whereas green firewood may be as high as 65%.

The extrusion production technology of briquettes is the process of extrusion screw wastes (straw, sunflower husks, buckwheat, etc.) or finely shredded wood waste (sawdust) under high pressure when heated from 160 to 350 C °.

Sawdust briquettes have developed over time with two distinct types: those with holes through the centre, and those that are solid. Both types are classified as briquettes but are formed using different techniques. A solid briquette is manufactured using a piston press that compresses sandwiched layers of sawdust together. Briquettes with a hole are produced with a screw press. The hole is from the screw thread passing through the centre, but it also increases the surface area of the log and aids efficient combustion.

Since 2009 in North India biomass briquette consumption has seen new dimensions. Many companies like Nishant Bio energy and Ekta Bio energy in Rajasthan are leading in the briquette supply and manufacturing.

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Biomass briquettes

Biomass briquettes are a bio fuel substitute to coal and charcoal. They are used to heat industrial boilers in order to produce electricity from steam. The most common use of briquettes are in the developing world, where energy sources are not as widely available. There has been a move to the use of briquettes in the developed world through the use of cofiring, when the briquettes are combined with coal in order to create the heat supplied to the boiler. This reduces carbon dioxide emissions by partially replacing coal used in power plants with materials that are already contained in the carbon cycle. Manufacturers mainly use three methods to create the briquettes, each depending on the way the biomass is dried out. Although biomass briquettes are usually manufactured, biomass has been used throughout history all over the world from simply starting campfires to the mass generation of electricity.

Composition and production

Bio coal briquettes have been introduced to meet the growing demand coal used

in burning and heating purposes. These briquettes are perfect to use in boilers and

are completely safe to environment.

Biomass briquettes, mostly made of green waste and other organic materials, are

commonly used for electricity generation, heat, and cooking fuel. These

compressed compounds contain various organic materials, including rice

husk, bagasse, ground nut shells, municipal solid waste, agricultural waste, or

anything that contains high nitrogen content. The composition of the briquettes

varies by area due to the availability of raw materials. The raw materials are

gathered and compressed into briquette in order to burn longer and make

transportation of the goods easier. These briquettes are very different from

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charcoal because they do not have large concentrations

of carbonaceous substances and added materials. Compared to fossil fuels, the

briquettes produce low net total greenhouse gas emissions because the materials

used are already a part of the carbon cycle.

One of the most common variables of the biomass briquette production process is

the way the biomass is dried out. Manufacturers can use

torrefaction, carbonization, or varying degrees of pyrolysis. Researchers

concluded that torrefaction and carbonization are the most efficient forms of

drying out biomass, but the use of the briquette determines which method should

be used.

Compaction is another factor affecting production. Some materials burn more

efficiently if compacted at low pressures, such as corn Stover grind. Other

materials such as wheat and barley-straw require high amounts of pressure to

produce heat. There are also different press technologies that can be used. A

piston press is used to create solid briquettes for a wide array of purposes. Screw

extrusion is used to compact biomass into loose, homogeneous briquettes that are

substituted for coal in co-firing. This technology creates a toroidal, or doughnut-

like, briquette. The hole in the centre of the briquette allows for a larger surface

area, creating a higher combustion rate.

History

People have been using biomass briquettes in Nepal since before recorded

history. Though inefficient, the burning of loose biomass created enough heat for

cooking purposes and keeping warm. The first commercial production plant was

created in 1982 and produced almost 900 metric tons of biomass. In 1984,

factories were constructed that incorporated vast improvements on efficiency and

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the quality of briquettes. They used a combination of rice husks and molasses.

The King Mahendra Trust for Nature Conservation (KMTNC) along with the

Institute for Himalayan Conservation (IHC) created a mixture of coal and

biomass in 2000 using a unique rolling machine.

Co-firing

Co-firing relates to the combustion of two different types of materials. The

process is primarily used to decrease CO2 emissions despite the resulting lower

energy efficiency and higher variable cost. The combination of materials usually

contains a high carbon emitting substance such as coal and a lesser CO2 emitting

material such as biomass. Even though CO2 will still be emitted through the

combustion of biomass, the net carbon emitted is nearly negligible. This is due to

the fact that the material gathered for the composition of the briquettes are still

contained in the carbon cycle whereas fossil fuel combustion releases CO2 that

has been sequestered for millennia. Boilers in power plants are traditionally

heated by the combustion of coal, but if co-firing were to be implemented, then

the CO2 emissions would decrease while still maintaining the heat inputted to the

boiler. Implementing co-firing would require few modifications to the current

characteristics to power plants, as only the fuel for the boiler would be altered. A

moderate investment would be required for implementing biomass briquettes into

the combustion process.

Co-firing is considered the most cost-efficient means of biomass. A higher

combustion rate will occur when co-firing is implemented in a boiler when

compared to burning only biomass. The compressed biomass is also much easier

to transport since it is more dense, therefore allowing more biomass to be

transported per shipment when compared to loose biomass. Some sources agree

that a near-term solution for the greenhouse gas emission problem may lie in

co-firing.

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Compared to coal

The use of biomass briquettes has been steadily increasing as industries realize

the benefits of decreasing pollution through the use of biomass briquettes.

Briquettes provide higher calorific value per dollar than coal when used for firing

industrial boilers. Along with higher calorific value, biomass briquettes on

average saved 30–40% of boiler fuel cost. But other sources suggest that cofiring

is more expensive due to the widespread availability of coal and its low

cost. However, in the long run, briquettes can only limit the use of coal to a small

extent, but it is increasingly being pursued by industries and factories all over the

world. Both raw materials can be produced or mined domestically in the United

States, creating a fuel source that is free from foreign dependence and less

polluting than raw fossil fuel incineration.

Environmentally, the use of biomass briquettes produces much fewer greenhouse

gases, specifically, 13.8% to 41.7% CO2 and NOX. There was also a reduction

from 11.1% to 38.5% in SO2 emissions when compared to coal from three

different leading producers, EKCC Coal, Decanter Coal, and Alden Coal.

Biomass briquettes are also fairly resistant to water degradation, an improvement

over the difficulties encountered with the burning of wet coal. However, the

briquettes are best used only as a supplement to coal. The use of cofiring creates

an energy that is not as high as pure coal, but emits fewer pollutants and cuts

down on the release of previously sequestered carbon. The continuous release of

carbon and other greenhouse gasses into the atmosphere leads to an increase in

global temperatures. The use of co-firing does not stop this process but decreases

the relative emissions of coal power plants.

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Use in developing world

The Legacy Foundation has developed a set of techniques to produce biomass

briquettes through artisanal production in rural villages that can be used

for heating and cooking. These techniques were recently pioneered by Virunga

National Park in eastern Democratic Republic of Congo, following the massive

destruction of the Mountain Gorilla habitat for charcoal.

Pangani, Tanzania, is an area covered in coconut groves. After harvesting the

meat of the coconut, the indigenous people would litter the ground with the

husks, believing them to be useless. The husks later became a profit center after it

was discovered that coconut husks are well suited to be the main ingredient in bio

briquettes. This alternative fuel mixture burns incredibly efficiently and leaves

little residue, making it a reliable source for cooking in the undeveloped

country. The developing world has always relied on the burning biomass due it

its low cost and availability anywhere there is organic material. The briquette

production only improves upon the ancient practice by increasing the efficiency

of pyrolysis.

Two major components of the developing world are China and India. The

economies are rapidly increasing due to cheap ways of harnessing electricity and

emitting large amounts of carbon dioxide. The Kyoto Protocol attempted to

regulate the emissions of the three different worlds, but there were disagreements

as to which country should be penalized for emissions based on its previous and

future emissions. The United States has been the largest emitter but China has

recently become the largest per capita. The United States had emitted a rigorous

amount of carbon dioxide during its development and the developing nations

argue that they should not be forced to meet the requirements. At the lower end,

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been done to the carbon dioxide levels. The major use of biomass briquettes in

India, is in industrial applications usually to produce steam. A lot of conversions

of boilers from FO to biomass briquettes have happened over the past decade. A

vast majority of those projects are registered under CDM (Kyoto Protocol),

which allows for users to get carbon credits.

The use of biomass briquettes is strongly encouraged by issuing carbon credits.

One carbon credit is equal to one free ton of carbon dioxide to be emitted into the

atmosphere. India has started to replace charcoal with biomass briquettes in

regards to boiler fuel, especially in the southern parts of the country because the

biomass briquettes can be created domestically, depending on the availability of

land. Therefore, constantly rising fuel prices will be less influential in an

economy if sources of fuel can be easily produced domestically. Lehra Fuel

Tech Pvt. Ltd. is approved by Indian Renewable Energy Development

Agency (IREDA), is one of the largest briquetting machine manufacturers

from Ludhiana, India.

In the African Great Lakes region, work on biomass briquette production has

been spearheaded by a number of NGOs with GVEP (Global Village Energy

Partnership) taking a lead in promoting briquette products and briquette

entrepreneurs in the three Great Lakes countries; namely, Kenya, Uganda and

Tanzania. This has been achieved by a five year EU and Dutch government

sponsored project called DEEP EA (Developing Energy Enterprises Project East

Africa) . The main feed stock for briquettes in the East African region has mainly

been charcoal dust although alternative like sawdust, bagasse, coffee husks and

rice husks have also been used.

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Use in developed world

Coal is the largest carbon dioxide emitter per unit area when it comes to

electricity generation. It is also the most common ingredient in charcoal there has

been a recent push to replace the burning of fossil fuels with biomass. The

replacement of this non-renewable resource with biological waste would lower

the carbon footprint of grill owners and lower the overall pollution of the world.

Citizens are also starting to manufacture briquettes at home. The first machines

would create briquettes for homeowners out of compressed sawdust, however,

current machines allow for briquette production out of any sort of dried biomass.

Arizona has also taken initiative to turn waste biomass into a source of energy.

Waste cotton and pecan material used to provide a nesting ground for bugs that

would destroy the new crops in the spring. To stop this problem, farmers buried

the biomass, which quickly led to soil degradation. These materials were

discovered to be a very efficient source of energy and took care of issues that had

plagued farms. 

The United States Department of Energy has financed several projects to test the

viability of biomass briquettes on a national scale. The scope of the projects is to

increase the efficiency of gasifiers as well as produce plans for production

facilities

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COMPANY PROFILE

COMPANY NAME : Gayathri Agro Tech (P) Ltd.

Bangalore Road

Challakere, 577535.

NATURE OF

BUSINESS : Mfg / selling based Industry.

OWNERS : Sudhakar

TYPE OF

OWNERSHIP : Sole Entrepreneurship.

TEL-NO : 098452 83086, 08195 223736.

E-mail : gayathribiofuels@yahoo.co.in

RAW MATERIAL : Saw Dust, Rice Husk

Groundnut shells.

TURN OVER : 7-8 lacs/month

FINISHED

PRODUCTS : Biomass Briquettes

OWNERS

INVESTMENT AT

STARTING : 25 Lacs

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GAYATHRI AGRO TECH

Gayathri Bio-Fuels established in the year 1991 near Hiriyur road, Challakere, Chitradurga

District, Karnataka as a manufacturer of Solid biomass briquette fuels. Gayathri Bio-Fuels

manufacture briquettes using the best grade of raw materials procured from reputed vendors.

Their product is widely appreciated by their clients for its reliable performance and high

efficiency.

Gayathri Bio Fuels has built its reputation by offering unparalleled quality briquettes and

service. They robust infrastructural facility equipped with the advanced machinery and

technologies enabling them to meet large scale orders of their clients. Their manufacturing

facilities are spread at different places.

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GAYATHRI AGRO TECH

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Introduction

Gayathri Agro Tech Ltd is the only industry that got success by manufacturing a different

product in Challakere. i.e. Briquettes made of the agro wastes such as coffee extracts,

groundnut shells, saw dust, Rice husk, Turmeric waste and chilli powder(waste).

First of all they starting their own manufacturing industry with the capital of 25lacs by

purchasing the machinery by Radhe Industrial Corporation at Challakere.

Now it is the leading industry in Challakere and they also own another two briquette

manufacturing plants in Challakere and one plant in Tumkur Industrial area.

A huge demand is there for the product that manufactured in the Gayathri agro tech.

They supplies there product to various states also such as Goa, Tamilnadu, Kerala and

Maharashtra also.

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MANUFACTURING PROCESS

RAW MATERIALS

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Calorific Value Of Raw Materials

Raw Materials Approx K Cal / Kg

Bark (wood) 3900

Bagasse (sugar Cane) 4200

Bamboo Dust 3700

Cotton Stalk 3800

Coir Pitch 4000

Maize Stalks 3800

Pine Niddles 4000

Rice Husk 3500

Rice Straw 3500

Sar Khanda Grass 3700

Coffee Husk 4200

Ground Nut Shell 4000

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Castor Seed Shell 4000

Jute Waste 4500

Mustarad Husk 4500

Sugar Mill Waste 3300

Sugar Cane Trash 3500

Wheat Straw 3700

Arhar Stalik 4000

Saw Dust 4000

Heavy Furnace Oil 9900

Kerosene 8900

Diesel 9400

Lpg 9400

Coal Grade 'b' 5000

Coal Grade 'c' 4000

Fire Wood 3300

Char Coal 6000

Calorific Value Of Briquette "white Coal" 4000

MANUFACTURING PROCESS

1. Material Like Saw Dust, Ground Nut Shells, Castor Seed Shells And All Another

Raw Material Up To 25mm Size Are Supplied To The Screw Conveyor.

2. When More Then One Material Is Used, Make Sure That They Are Mixed In

Suitable Proportion.

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3. Materials With Higher Moisture Content I.e. More Then 10-12% Needs To Be

Dried In Sunlight.

4. Material From Conveyor Is Discharged With The Help Of Conveyor, Veram And

Gear.

5. Material In The Feeder Box Is Compressed By The Press, Forcing It Through

Tapper Die (ram Punch) Fitted In The Die Holder.

6. The Compression Raises The Temperature Of Material Which Results In

Softening Of The Lignin, Inherent In Every Biomass. This Lignin Comes To The

Surface And Binds The Materials Together.

7. Briquettes Formed Are In The Shape Of Logs Which Are Pushed Through Cooling

Tracks Under Slight Pressure For Cooling And Transport Storage Point.

8. Cooled Briquettes Are Broken & Packed In Bags Or Stored In Bulk For Dispatch.

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BRIQUETTE PROCESSING MACHINE

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Quality

Gayathri Bio-Fuels manufacture and supply the finest quality Briquettes for Industrial use, which are processed using an amalgamation of groundnut shells, saw dust and coffee husk. 

Infrastructure

Gayathri Bio Fuels have two manufacturing units at Challakere and one at Tumkur. Gayathri Bio fuels are also the largest manufacturer of industrial Biomass Briquettes in the country with the production capacity of 5000 Mt/Month. 

Gayathri Bio Fuel’s Concerns

The sister concerns of Gayathri Bio-Fuels are as follows

Gayathri Agro-Tech (P) Ltd.

Challakere – 577 522

Surabhi Bio Fuels

Somaguddu road, Challakere

Gayathri Bio-Fuels

Plot no 140, 2nd phase,

Antharasanahalli Industrial Area

Tumkur, Karnataka

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Why Industries prefer Gayathri Bio Fuels

Eco-friendly Bio-Mass Briquettes

Timely Delivery

Economical Price

Customers’ Satisfaction

A number of companies in India have switched  from furnace oil to biomass briquettes to

save costs on boiler fuels. Use of biomass briquettes can earn Carbon Credits for reducing

emissions in the atmosphere. Biomass briquettes also provide more calorific value and save

around 40 percent of boiler fuel costs.

Bio-mass briquette is one which takes agriculture residues such as saw dust, groundnut shells

and coffee husk and compresses it to make solid Briquettes. There are no binders involved in

this process. The natural lignin in the wood binds the particles of wood together to form a

solid briquette. Burning a wood briquette is far more efficient than burning firewood.

Moisture content of a briquette can be as low as 4%, where as green firewood may be as high

as 65%.

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Specification.

Size: 90mm Dia. with variable length of 4" to 6"

Ash Content: About less than 10%

Moisture Content: less than 10%

Calorific Value: between 3800 to 4200 Kcal / Kg

Chemical contents: Sulphur – Nil 

                               Phosphorus – Nil

Advantages of Briquettes

Briquettes are cheaper than coal.

High sulfur content of oil and coal, when burnt, pollutes the environment.There is no sulfur content in

briquetted fuels.

Briquettes have consistent quality, high burning efficiency, and are ideally sized for complete

combustion.

Combustion is more uniform as compared to coal and boiler response for change in steam requirements

is faster due to higher quantity of volatile matter in Briquettes

A Briquette is an Ideal Fuel due to

Eco friendly and Renewable Energy Fuel.

Economical and Cheaper than other solid fuels ie. Coal and Wood.

Higher Thermal calorific value around 4000 Kcal/Kg.

Pollution free because there is no sulphur or any hazardous materials.

Lower ash content 4 to 8 %.

Consistent high burning efficiency due to the low moisture.

Contain High Density and Higher Fix Carbon Value.

Easy for Transportation, feeding & combustion due to unique shape.

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Combustion is more uniform compared to other fuels.

Good Market due to rise in price of Fossil Fuels

Agro Residue briquettes have benefits over coal like

Easy handling, packing and transportation of briquettes can be made in any conventional length and

diameter.

Low ash content below 10% in comparison to coal 25 to 40% resulting in less boiler ash disposal

problems.

There will be no corrosion effect on boiler equipments resulting in negligible maintenance cost. Coal on

the other hand produces sulphur dioxide, which on mixing with moisture produces sulphuric acid,a

corrosive acid.

It has low ignition point, when compared to coal.

 It gives sustained combustion and more efficient combustion than loose agro wastes.

It is a clean fuel.

No gas and effluents like coal. So no health hazards.

Easy Handling compared to loose husk and fire wood. Can be mixed with coal and fire wood of inferior

quality which improves burning.

Briquettes are Cheaper than coal.

High Sulphur content of oil and coal, when burnt, pollutes the environment. There is no sulfur in

briquettes. Biomass briquettes have a higher practical thermal value and much lower ash content 4-8 %

compared to 20-40% in coal.

Briquettes have a consistent quality, have high burning efficiency are ideally sized for complete

combustion. Combustion is more uniform compared to coal and boiler response to change in steam

requirements is faster due to higher quantity of volatile matter in briquettes.

Briquettes are usually produced near the consumption centers and supplies don't depend on erratic

transport from long distance.

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Uses of Finished Briquettes in various Industries (Thermal Application)

Gasifier System applications

Refractory Industries

Chemical Industires

Vegetable Plants

Leather Industries

 Milk Plant

Rubber Industries

Textile Units

Dyeing Units

Brick making units

Ceramic Industries

Solvent Extraction Plant

Steam generation for various industrial applications

Distilleries

Food Processing Industries

Lamination Industries

Any Industrial Thermal Applications

Bio coal is a forth coming fuel of the world. It's a high quality asset towards economical, ecological and advanced environmental company policy.

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HUMAN RESOURCE

Human resource in this industry means workers that are working in this

industry. Gayathri agro tech provided more employment opportunities

to the surrounded village’s people. There are 100 - 120 workers

working in this industry in different section of manufacturing process.

Incentives and Bonuses have been given for motivating them to

undertake more and more production work.

Direct Labour : 40

Indirect Labour : 80

Wages per day : 100 – 120 Rs.

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FINANCE

As seen in the Gayathri Bio Fuels Industry, there is a huge capital that the industry have. That is they invested approximately 25 lacs at the time of establishment, But now the total capital may approximately 6 – 7 crores.This industry have well financial system that meets all working capital requirements.

Investment : approx. 25 lacs

Total Capital : approx. 6-7 crores

Turn over : approx. 15-20 lacs

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MARKETING

Marketing is the last process that all the industries have. In Gayathri Bio Fuels industry their marketing is well because they supplies their product to various states also like Goa, Kerala, Tamilnadu and Maharashtra. And they supply in karnataka viz. Bangalore, Hassan, Bellary also.

Mode Of Transportation : lorries

Selling Price/ton : 4800 Rs.

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SWOT ANALYSIS

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Strengths

They have good brand and image in all over south India.

They provide fair wages to the labours.

They manufacture good briquettes.

They facilitate the farmers to sell their agro wastes to the

industry.

They are using Modern technology.

They have well equipped machineries.

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WEAKNESS

They Doesn’t have their own transportation facility.

There is scarcity of Raw materials hence the production will be

lower in the time of scarcity.

There is a scarcity of workers also.

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OPPORTUNITIES

They can use latest technology of manufacturing the Briquettes i.e.

Radhe industrial corporation invented another fast making machine

called “JUMBO” for making the production faster that leads to

meeting the demand.

There is no other manufacturer in surrounding hence this as an

strength as well as opportunity.

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THREATS

The Raw materials suppliers are not supplying the raw

materials sufficiently hence this causes the problem.

If Raw material is not stored in the godown means it will

case the dryness of moisture content.

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FINDINGS

SUGGESTIONS

CONCLUSION

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FINDINGS

As all know that Gayathri Bio Fuels industry having a good

brand and image

They provide good wages to the workers

They established the industry with well furnished resources

They have their own vast land

They have a good financial system

They have good production system

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SUGGESTIONS

They can make their production even faster by using the

modern technology.

They can use other natural raw materials to produce

briquettes hence this will cover the uncertainity of raw

material supply.

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CONCLUSION

As we seen that this industry is very well furnished with the

finance and machineries and land with all resources. We

learnt lot of things by visiting this industry.

PHOTO GALLERY

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Mr.Sudhakar giving information about their industry

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Stock of saw dust in the godown

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Briquette

Briquette Manufacturing machine

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