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Chapter 1
INTRODUCTION

Background of the Study

In this modern time, energy is crucial. Consumers harness energy to induce

electricity for daily works at homes, schools, industries, and businesses. In year 2017, the

Global energy demand increased by 2.1% which is two times greater than the previous

annual rate, uplifted by powerful global economic growth, with oil, gas and coal which

encountering the most enlarge demand for energy, and renewables ensuring great benefits

(International Energy Agency, 2017). Within this global energy demand growth, more

than 70 % of total demand growth rate was encountered by oil, natural gas, and coal,

although the rest was renewables.

In particular, cooking consumes 90% of total energy (Bogale, 2009). In rural

areas, most families use wood charcoal for cooking because of its thermal advantage.

Specifically, charcoal is hotter and cleaner than a regular wood. However, in most

countries, a vast deforestation is in progress, which is why the supply of woods for

charcoaling is short. Moreover, it may cause price inflation in charcoal , yet the heating

value is low, owing to the fact that the density of the wood is low, and the consistency of

wood charcoal is less. Wood charcoal can be replaced by one that is made from

agricultural waste which could be a potential source of energy for cooking.

Agricultural waste is the best possible source for charcoal (Bogale, 2009). When

harvesting different crops, mostly the farmer only harvests the grains, fruits and coffee,

pods and tubers. This is only composed of 30% - 40% of total biomass which means that

60 % - 70% of total agricultural biomass is a waste made annually (Bogale, 2009).

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Agricultural wastes such as coconut husk, coconut shell, coffee husk, grass, and among

others can be used as charcoal briquettes that can be an alternative source of energy.

Consequently, it may help lessen the use of wood fuel, which means deforestation and

illegal logging may also be addressed.

Charcoal briquettes are produced from raw material such as coconut shell, palm

shell, and sugar cane bagasse that are blazed or pulverized to be a powder (Somsuk,

2008). These are made to enhance regular charcoals aspects, such as increase in heating

value, smokeless, odorless, and fast or low burning time. Charcoal briquettes are

considered as renewable source of energy, which are environment-friendly, and could

help in minimizing carbon quantity in the atmosphere.

Yet the machine cost for charcoal briquette is slightly high for small scale

organization. Some organizations which could not adapt high end briquetting machine,

such as small scale livelihood organizations, are found in developing countries. In the

Philippines for instance, these livelihood enterprises face challenges in acquiring this

machines because of its high cost. One of these enterprises is the Tree’s a Life, a

livelihood organization providing job opportunities for disabled individual in Santa Ana,

Taguig. Tree’s a Life produces briquettes from raw materials like coconut husk, water

hyacinth, and to name a few. Currently the organization is expanding and experiencing

high demand for the briquettes. However, the organization is having difficulty meeting

the growing demand for their eco-briquette as a result of their manual-based process of

producing their products. Moreover, being a start-up, the enterprise is yet to establish

itself, hence still incapable of purchasing high-end equipment to increase their

production.
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In this light, the researchers propose a low cost yet high efficiency machine for

small scale charcoal briquette producers. It is designed to be safe, easy to control, and

capable of molding high quality briquettes. The machine has general features of

compression, lifting and ejecting, hopper and control box. The compressing section will

make all the required characteristic of briquettes; more denser and more efficient

briquettes. The lifting and ejecting section is controlled by one motor; all the movement

of the machine is synchronized and controllable. A hopper is a funnel-shaped material

used for storing a grain, animal food, or coal. It will help the machine to transfer the

briquettes mixture to compression section of the machine. A control box is composed of

buttons and switches. In this section the user can control the machine easy and no hustle.

Objectives of the Study

The main objective of the study is to develop a briquetting machine that would

improve the efficiency of eco-charcoal production.

Specifically, the study aimed to:

1. Design a developed briquetting machine with the following

features:

a. It has mechanical mechanism that uses sprocket and chain

to drive simultaneously the compressing, lifting and hopper

sections.

b. It has a briquette molder consist of 11 holes that is made of

steel plate and stainless steel

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c. It has 2hp single phase gear motor to run the chain drive in

order to produce the briquette charcoal

d. It has Proximity Sensor that signals the buzzer when the

pulverized raw material in the hopper is not suffienct to fill

the cylinder molder.

e. It has control system composed of push buttons, pilot lamp,

Relay, Limit switch and timer to control the AC motor and

agitator. A circuit breaker and overload relay for safety

purposes.

f. It has solenoid lock for locking the lifting section in order

to eject the briquette charcoal.

g. It has safety feature that shutoff the system when the

maintenance roll-up door is open.

2. Construct the prototype using locally available materials.

3. Test and improve the prototype by comparing the output between

the normal briquetting in terms of production.

4. Evaluate the performance of the prototype in terms of

functionality, workability, durability, if it is economically and in

terms of safety.

Scope and Limitations

The study involves the development of eco-briquetting machine which could

improve the manual process of charcoal briquette production. The project is to be

constructed using locally available materials which will automatically mold the products
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mixed from agricultural waste to produce an efficient charcoal. The machine can be used

by putting the charcoal mixture, compressing and molding high quality products needed.

However, the study is limited to eco-waste material only. It is designed especially

for agricultural waste materials to make a high quality, more efficient and more

sustainable product briquettes. The machine is operated by single phase motor. The

machine will require a 220-230 volts, 60 Hz AC supply. The machine can operate up to 8

hours running time.

Significance of the Study

The study intends to make a machine that will help small scale organization like

Tree’s a life in producing charcoal briquettes. A machine that will cost lesser than the

other machine built. A machine that produces highly sustainable, more efficient and

harmless briquettes. An easily controlled and user friendly machine that could be

convenient to use even by person with physical disabilities.

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Chapter 2

CONCEPTUAL FRAMEWORK

This chapter presents the review of related literature and studies underlying the

framework of the study. It includes the conceptual model of the study and the operational

definition of terms.

Review of Related Literature and Studies

Charcoal

Charcoal is the impure form of natural compound and obtained from ash residue

of wood, bone or other organic matter. It is also classified as a type of half burnt wood.

The most common material used as alternative fuel in some workplace because of its

capability to burn hotter than a usual LPG gas. It is widely used in any different aspects

such as making bronze by melting copper and tin.

The process of doing a particular chemical has been diminished by coke to charcoal

that lessen the metal ores in blast furnace and natural gas as a source of carbon. Perhaps,

it is still accommodated in doing black gunpowder and in case-hardening metal. In the

past, charcoal production from wood was an important source of acetone, methyl,

alcohol, and acetic acid, all of which are now produced from other raw materials.
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Figure 1. Charcoal
Source: www.quatr.us

As shown in Figure 1, this is how charcoal looks like and it can be obtained from

different raw materials of woods, bones and other organic matter.

Charcoal is the foremost thing that people usually used since 4000 BC in both

china and West Asia. Some other people such as north and south American people and

Europeans also made and used charcoal. The process of doing charcoal was merely

different from the modern civilization. By piling wood up and covering it with dampened

dirt and then lighting the wood on fire, so that it burned very slowly without much

oxygen. In early 90’s, burning of hard wood like oak or beech can help to have better

charcoal and the result is mainly carbon like coal (Carr, 2017).
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Figure 2. Charcoal Hut

Source: www.quatr.us
People also benefited from the advantages of this charcoal just like in the slum

area of charcoal factory near manila. Hundreds of families earn a lot from the charcoal

industry, even the air is thick with smoke children and adults get to work. Families have

lived there for generation even to that condition but local government is helping to ensure

that there will be no harm will happen and a few decent meals a week and some

education will be granted (De Leon, 2012).

Figure 3. Piles of wood

Source: www.theguardian.com

Figure 3 illustrates the way people of charcoal factory made charcoal was

generally need to stack wood to burn slowly for three days and each day is spent making

piles of scrap of wood into charcoal. The charcoal factory consist of areas of shallow

earth pits enclosed by makeshift fences.

In line with these ideas the journal of De leon (2012) tends to give the situation of

what people faces on making charcoal and on some point tackled the particular needs of

manufacturer. But then Carr (2017) tackled the root of all, where and how charcoal

started. The two gives much more ideas on bringing charcoal industry in the modern
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society and how it will work as an appropriate material to used. It helps the project to

understand the purpose and importance of having an alternative resources to produce

charcoal to avoid deforestation and any prohibited action of human kind.

Uses of Charcoal

Production of charcoal has an abundant effect on the Philippines, especially in the

southern region. In some other places like in the Mindanao islands, producers used to do

the traditional way of making charcoal which is ground-pit method of production. It has a

lot of purposes that drives everyone’s life. It can be used as deodorizer, maintaining

youthful skin, and can be a remedy for a certain diseases (Philippine Primer, 2018).

As a Deodorizer

Charcoal has a physical property that can freshen and remove unwanted odors.

This can be placed anywhere, either put it in refrigerator, cabinet or inside the living

room and kitchen. The good thing about using it as deodorizer is that it can last for a

long time, given that it is also used for cooking and the convenient of using is comparable

than other artificial material.

Figure 4. Pieces of Charcoal

Source: www.pixabay.com

Figure 4 shows an image of a pieces of charcoal used as deodorizer.

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As a Beauty item

The numerous effect of charcoal has been emerged to the modern society and

making improvements in generations. It is now applied to skin and made wonder result.

Preventing skin from irritation and acne, at the same time serves as a vacuum to pores. Its

properties will help the skin to reduce the impurities and inflammation.

Figure 4. Beauty Item

Source: www.hercampus.com

As shown in Figure 5, charcoal is used in beauty product like facial sponge and

deep cleansing charcoal pore strips which the strips can remove the blackheads and oil

and prevent skin from irritation and acne.

As a Toothpaste

Oral hygiene is every day’s normal practice of people, and activated charcoal is a

great potential to use as toothpaste. This can prevent cavities, gum disease and bad breath

according to study. It is also known to whiten the teeth with regular brushing, much like

regular toothpaste but with fewer chemicals.

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Figure 6. Charcoal Toothpaste

Source: www.coolmaterial.com

As shown in Figure 6, active charcoal also can be use as toothpaste. According to

Dr. Burhenne (2018) active charcoal can balance your oral microbiome, can prevent

cavities, remineralize teeth and lastly it will improve bad breath.

Figure 7. Remedy Charcoal

Source: www.pixabay.com

As shown in Figure 7, activated charcoal can also be an emergency toxin removal

in times of need. During an unexpected occasion, activated charcoal can prevent the

absorption of the chemical. According to the University of Michigan Health System, 50

to 100 grams is used in cases of poisoning in adults and 10 to 25 grams for children.
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Aside from this, activated charcoal can help those suffering from diarrhea or food

poisoning.

Lump Charcoal and Briquette Charcoal

Lump charcoal is a type of carbonized scraps such as wood, saw mills, flooring,

furniture and building materials. These materials are carbonized through the process of

making charcoal but then some manufacturers do not used building materials. The output

will be lumps that are irregular in size, often looking limbs and lumber (Goldwyn, 2010).

There are no binders in lump charcoal that is why it produces less ash than

briquettes. The big disadvantage is that lump is harder to find, more expensive than

briquettes, burns out more quickly, varies in heat output per pound, varies in wood type

from bag to bag, and rough handling in the stores. In some countries who are not often

experiencing tropical season lump charcoal is quite larger than briquettes making it not fit

to chimneys.

Figure 8. Charcoal Briquette and Lump Charcoal

Source: www.amazingribs.com

As shown in Figure 8, the briquette charcoal is produced by a briquetting machine

than burns out more lasting while lump charcoal is composed of carbonized scrap such
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woods, furniture, saw mills and saw dust it is more costly and it will immediately burnt

out.

Charcoal Briquettes

Charcoal briquettes exist when in the 1920’s, Henry ford in collaboration with

Thomas Edison and Kingsford, made lots of briquettes from saw dust and wood scraps.

In that time, car bodies are made up of wood. So Ford not only brought the world

affordable cars, he created an industry that made backyard barbecue easy (Goldwyn,

2010).

Briquettes are made of two primary ingredients (comprising about 90% of the

final product) and several minor ones. One of the ingredients, known as char is basically

the traditional charcoal. It is responsible for the briquette’s ability to light easily and to

produce the desired wood smoke flavor. The most appropriate raw material for this

component is hardwoods such as beech, birch, hard maple, hickory, and oak. Some

manufacturers also use softwoods like pine, or other organic materials like fruit pits and

nut shells.

Disadvantages of Charcoal

The potential of charcoal has made its own limitation to commercial and industry.

When it is used as cooking partner it only last 30-40 minutes and once it reaches its peak

temperature it starts to cool quite quickly. The tendency to put more charcoal means that

it can take another ten to fifteen minutes to reach temperature. But briquettes can

overcome this problem as it burns up to 3 hours with fairly even (Slater, 2018).
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The common problem that can be noticed on managing the balance heat of

charcoal is probably determined because of its uneven sizes. However, by developing an

alternative product such as briquettes, it can prevented from happening because of its

capability to give sufficient heat.

It cannot be deny that the production of charcoal is contributing to the wide

deforestation in many countries. The increased in production of charcoal affiliates a

demand for the source of the product which is mainly came from the forest. In order to

sustain the profits of small scale businesses the production takes place inside the market

to lessen the cost of transporting. Despite of the several problems, the local community

can benefit to the abundance supply of raw material given by the forest.

Giz Hera (2018) connotes that, while the process of carbonization is occurring, it

produces a greenhouse gas emission ranging between 7.2 and 9.0 kg of CO2 and that is an

equivalent of charcoal produced per kilogram. However, a developed kiln technology can

do a solution for this problem, which can decreased the greenhouse gas emission without

affecting carbonization’s efficiency. But the problem is there is still no progress on

adopting the concept of a kiln because of informal and illegal nature of charcoal

production. In places where raw material is consistently available there is possibility

progress on improving the production.

Emerging practices and machines made through years that has improper

construction has also contributed to the widening range quality of air produced in

environment. Some sections on the process of production, emits some harmful gases and

particulate matter on the working environment of the worker. Particularly, burning is

included to the process of making a charcoal but burning of raw material may lead to a
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respiratory failure and to illnesses such as asthma, lung cancer and other infection that

caused by heat and smoke.

Furthermore, Charcoal also has a lot of advantages because of its properties that is

why it is used in so many ways (Philippine Primer, 2018). Philippine primer promotes the

importance of charcoal and how it will improved and help the small scale business in the

industry. However, Angela Slater (April 28) point out that these advantages has its

limitation. The high production of charcoal means that high percentage of deforestation

will be. Most of charcoal acquired from wood and wood is gain either from scrap or from

forest. These ideas gives knowledge and background to the researchers to formulate a

good output for future project.

Alternative to Charcoal

Eco-Charcoal

When the time of late nineteenth and early twentieth centuries, the byproduct

acquired from acetic acid and methanol by wood charring process became the foremost

product, where the charcoal itself become eventually the byproduct (Hennig, 1992). In

the end of improving an efficient and less costly techniques for synthesizing acetic acid

and methanol, charcoal production made its way significantly until it was revitalized by

the development of briquettes for recreational cooking.

The capacity of wood charring process is to produce a certain amounts of

particulate laden smoke. To reduce the emission as much as 85% there must be a exhaust

vents with after burners, but particularly this cannot be done because of its high cost

treatment and it is uncommon used.

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Some of the constant level of operation of retorts does it easier to control the

emissions with afterburners, but it allows for productive use of combustible off-gases.

These gases can be used as fuel wood dryers and briquette dryers or to produce steam and

electricity.

It is very common knowledge that charcoal briquette production is

environmentally friendly just like in the largest briquette manufacturers in the United

States uses only waste materials or scraps for its wood supply. The typical material to use

are wood shavings, sawdust, bark from pallet manufacturers, flooring manufacturers, and

lumber mills and these are converted from piles of scrap into useful briquettes.

Table 1

Typical analysis of wood as raw material

Air seasoned 15-20% moisture content

dry 2-8% moisture content
specific weight 0.47- 0.7-8kg/dm3
av. Chemical composition(% by weight) C= 50.6%, H2=6.2%, O2-42%

Table 2 shows the moisture content of wood raw material depending on air

seasoned and dry.

Types of Eco Charcoal

Charcoal is one of the most important creation of people when it comes to

technological aspects, it was used as early as 200,000 B.C charcoal was produced due to

burning of wood slowly without oxygen. By charring process it removes water and most

of the flavor producing chemical compounds of the wood, leaving a carbon rich fuel that

burns hot, cleanly and efficiently. Charcoal also produces more concentrated fire.
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Lump charcoal

This is one of the original charcoal and it is sometime called as charwood or

natural lump charcoal. This was made from trees or logs in a kiln, sealed cave, or even

underground. Compare to other types of charcoal, lump charcoal is a pure wood and it is

free binders or petroleum based accelerants. It has its property to burns hotter, clean and

pure. And it can be also refuel with any unlit charcoal. However, its burning time is

unevenly, it can be hotter at the beginning the cooler at the end and it burns out more

quickly than charcoal briquettes.

Charcoal briquettes

Briquette is a type of charcoal and designed to burn evenly and maintains a steady

broiling temperature of atleast 600 degress Fahrenheit for one hour. This is mainly

consist of wood scraps, sawdust, coal dust, and petroleum binders so it’s possible that it

emits an acrid tasting smoke when it is first lit.

Instant-light charcoal

This type of charcoal consists of briquettes saturated with lighter fluid. When its

fire starts to glow as orange its acrid smoke disappears and begin to ash over. It can

produce an oily taste when it is completely lit. But natural briquettes which contain wood

scraps and starch binders are the only that can vanished that problem.

Binchotan
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This is one of Japan’s kind of charcoal, it is the super-premium lump charcoal of

Japanese people. In japan it used in top of yakitori parlors and then in United States. This

charcoal is traditionally made from ubamegashi oak in mud sealed caves in southwest

japan. It has the capability to burn very clean and hot, producing no unwanted charcoal

flavor.

Figure 9. Binchotan
Source: www.wikipedia.com

As shown in Figure 9, binchotan is fineness and high quality to steaming at great

temperature is about 1000 degrees Celsius by cause of it does not discharge unpleasant

odours.

Coconut shell charcoal

In some countries such as Thailand, coconut husk make its way to be a fuel that

fires ten thousands of grills. It is really quick to light, to burn and sold in small pieces.

This is mostly used by Asian street vendors because it is perfect fit for small grills.

Extruded Charcoal

It is a new process of producing a charcoal, gain through either on sawdust or

ground coconut hulls. This will be pressed through a heated mold under high pressures to

form a log that can then form into charcoal through traditional processing. Some
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manufacturers claim extruded charcoal produces less smoke while lighting and burning,

less ash, longer burning of time, odorless, and binder free.

Sugar Charcoal

It is a type of charcoal that comes from the carbonization of pure sugar. To

remove any mineral matter, sugar charcoal will be purified by boiling with acids then

burned for a long time in a current of chlorine in order to remove the last traces of

hydrogen. This was first used when Henri Moissan tends to create synthetic diamonds.

Activated charcoal

It has similarities to common types of charcoals but the purpose of this is for

medical used. By heating the a common charcoal in the process of a gas it causes the

charcoal to develop many internal space or pores these pores help activated charcoal trap

chemicals. Due to this process manufacturers produce activated charcoal.

Characteristic of Eco Charcoal

The characteristics of Charcoal depends on the process of carbonization and the

raw materials that are being used. Charcoal is a highly porous and brittle material and

then now has a bigger role in the industry that valued by people. But nobody understand

the mechanism by which charcoal is associated to work, from either physical or chemical

aspects (Ukrainian Biofuel Supplier, 2015).

The preparation of charcoal is the basis of either lump, briquette or extruded

forms. The misunderstanding of people to think that charcoal can last longer and burns

hotter must be consider as a common mistake.

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Figure 10. Porosity of Charcoal as the Main Physical Property

Source: www.ukrfuel.com

Figure 10 illustrate the foremost physical property of charcoal is its particle size,

this plays as good influence for its absorption properties. Hence, its porosity gives

charcoal capability to attain the absorption of soil liquid. Its wide surface is due to the

fact that various particles of charcoal has thousands of crevices, pits, grooves, and holes

which, when opened out make a quite high surface area.

Charcoal has volatile content causing it to ignite faster. But somehow this may

cause more smoke during the combustion and a reduction in the heating value of the

charcoal. The typical volatile content of charcoal that domestically used is approximately

between 20 to 30 percent. Hence, increasing the pyrolysis temperature removes more

volatile material and also tends to reduce the oxygen or carbon and hydrogen or carbon

ratios. The properties of various charcoal acquired form different sources and produced at

various temperatures.
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Figure 11. Conductivity and Density on Charcoal’s Physical Properties

Source: www.ukrfuel.com

Charcoal is not a good material as a conductor of heat and electricity. As shown in

Figure 11, its arrangement of carbon atoms is in irregular state where there is no free

movement of electrons attached. But there is responsible for the poor conduction of heat

and electricity in charcoal. It is highly porous in nature because sometimes charcoal

present as powder.

One important property of charcoal is its density, it can control the tendency of

charcoal to sink or float and to erode or remain on the land surface. Its density depends

on the raw material used but its estimated density can vary between 0.2 or 0.6 t/m3. The

product produce from hardwood as raw material is heavy and strong, whereas produced

from softwood is soft and light. Also the size distribution can be a factor in a bulk

density. In addition, as specific gravity increases the absorbing power of most kinds of

charcoal will increased too.

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The temperature and material used in the process will vary on the physical

property of charcoal. As charcoal contain certain amounts of hydrogen and oxygen as

well as ash and other impurities the structure and properties of charcoal can be

determined. High porosity, low density, bad heat and electricity conduction is the most

important characteristic of a charcoal. However, the scientist have not explored much in

the mechanism of charcoal as its physical properties are so poorly understood that then

there is still more to know about it.

Charcoal Production

The impact of charcoal production is widely open in tropical countries in the

world, because of the massive effect on ecological and environmental aspects,

government, public forestry institutions and non-government organization imparting

themselves about these charcoal related impacts (Chidumayo, 2012).

It requires a certain sequence of steps on charcoal production chain, and it must

be carried out in the correct order because that is the most important thing. It varies

incidence on production cost. The most costly links of the production chain must be

concentrated of the attention to enable the importance of each step or unit process.

Procedure

There is a traditional way of making a charcoal and that is through kiln, kiln will

be loaded of wood and burned to dry the wood and it must have higher temperature to

starts the pyrolysis and to continue the completion by its self. Due to the ingenious way

the success rate of sophisticated retorts in producing high quality charcoal in which it

make use of the heat pyrolysis, normally wasted, to increase the temperature of the

incoming material so that pyrolysis is accomplish without burning additional wood. In

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some instance it is really needed that heat impact be acquired for heat losses through the

walls and other parts of the equipment. To dry the wood carbonizing wood can be used to

burn to provide a certain heat needed to dry it.

Charcoal is obtained through the process of pyrolysis which contain of carbon,

together with a less amount of residue. The ash mainly content of the original wood,

combustible gases, tars, a several chemicals such as acetic acid and methanol and a large

amount of water which is given off as vapor from drying and pyrolytic decomposition of

the wood.

The process of making a charcoal can be divided into different steps or operation

and these operations are growing the fuelwood, wood harvesting, drying and preparation

of wood for carbonization, carbonizing the wood to charcoal and lastly the screening of

the storage and transport to warehouse or in any distribution point.

The production can be costly but then it can be analyzed by following the cost

centers which shows the clear advantage of using this process. First, the cost of fuelwood

placed at the side of the kiln, pit or retort, including financial cost. Also carbonization

labour cost including loading and unloading. The third one is the cost of transport of

charcoal to major markets or distribution points. Cost of working capital and fixed

investment cost of the pits, kilns or retorts. These are just the examples of key points on

finding a way of computing a cost of a production.

Charcoal has different types based on size, uses, and structure but, Ukranian

Biofuel Supplier (2015) leaves a content on the characteristics or properties of charcoal

and Chidumayo (2012) gives concern on the charcoal production. However, Hennig

(1992) explains how the charcoal itself essentially become the byproduct. Charcoal
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production declined significantly until it was revitalized by the development of briquettes

(Hennig, 1992). These ideas gives an information about briquetting. In addition, it also

help the researchers to figure out how the project is going to be constructed and built in

purpose and it also give ideas on how charcoal should be created.

Briquetting

Briquetting is the process of molding a briquettes. A briquette is normally

obtained from natural materials such as agricultural waste, forestry waste, seed covers,

coal pieces that are compressed during the process it is either mold as block or any

regular size. Briquettes are alternative sources for non-renewable fuel which is so

environmentally friendly. It poses no harmful effect on the environment because it does

not emit any harmful gases. The briquettes is mainly used as fuel, coal, cooking and in

boilers.

This is the most common used practice even in modern generation of compaction

technologies for densification of waste materials to make it more useful in other way. The

raw materials that mainly used for briquetting are coal, charcoal, wood, saw dust, paper,

stalks and other materials that are classified as waste of agriculture, forestry, and any

organic material. These raw materials will be compressed on the machine to get a

briquette that shaped uniformly. The size and shape of the briquettes is depending on the

application or how and where it will be used.

The first process of briquetting will be crushing the raw material into small pieces

to make it compressed clearly and burn easily. Some of the crushing machine is locally

available in the market that is why manufacturers don’t deal with it too hard. Briquette

can be located in areas that are needy of fuel or in some cases the cost of fuel is much
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higher. That is why briquettes is one of most common option to use because of its price

and easy way. Its main advantage compare to other charcoal is that it does not require any

binder to bind the raw materials together to form a briquette. Or is the reason why it is

also called as binder less technology.

Briquettes is chosen than other products like coal and other renewable fuel that

are hard to obtain and generate. The high caloric valve of the briquette made it so

advantageous because it makes briquette easy to ignite. The key factors of briquetting are

low production cost, waste material management and conversion of economic waste into

something useful.

Briquetting Machine

Manual Briquetting

Hand operated or manual briquetting machine was done to meet the designated

domestic energy demand in rural areas. Manual operation is sometimes essential for users

who wants to assure the quality of the product produced on a certain time. A hand

operated briquetting machine is purposedly evaluated for analysis of product it produced.

Raw materials used for machine are rice husk, dry leaves, groundnut shells and sawdust

along with paper pulp as binding material for preparation of briquettes. It has an average

capacity of 5 kg. h-1. Bulk density of biomass after the process of briquetting is increased

by 2.3, 2.6, 2.6, and 2.5 times for rice husk, dried leaves, groundnut shells and saw dust

respectively. For groundnut shells briquettes, showed high resistance to shattering,

followed by saw dust briquette. Then the briquette from dry leaves showed high

resistance to water penetration. And it is found that using briquettes in local areas satisfy

the needs of a consumer.

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This sample hand compression low pressure biomass briquetting machine is

designed to create charcoal by circular motion of its rod in clockwise direction. It

contains different parts and these are screw plate mechanism, body frame and cylinder,

support stand and other ancillary parts. (Mondru, 2012).

Figure 12. Charcoal Briquettes

Source: www.researchgate.net

Figure 12 shows an image of the machine designed to be placed on a level ground

to operate, and its steering arm can be rotated to bring to the top position. When biomass

raw material fed on the cylinder through the opening, the screw rod should be rotated in

clockwise direction. And then it will be pressed downward by the compression metal

plate. During the process, most of the liquid will fill out of the cylinder through holes.

Motorized Briquetting Machine

There is an example of motorized briquetting machine which is a screw type

extruded unit. This is a model of briquette making machines suitable for preparing

cylindrical briquette from charred biomass, coal powder, and carbon black. The machine

has a feeding hopper where raw materials will be put in to prepare the mixing of charcoal
 27

with the cow dung along with predetermined proportion of water. The Feeding process of

this machine is slightly done slowly. From the feeding, hopper the raw material moves

towards the outlet end where the opening forms the die through which the briquettes

come out continuously. And then the collected briquette will be left in the sun for drying.

Existing Briquetting Machine

This automated briquetting machine has an induction motor that fitted with a

variable frequency drive to control the motor’s rotational speed. It uses Programmable

Logic Controller (PLC) to manage all the controls of the briquetting system and to make

synchronized all sensors and drivers. In addition, the machine has also feature to control

the panel for safety and give ease to operation. This machine do the simulation to know

the optimal design configuration of the screw geometry applicable for automation. And

the experiment performed by depending on the temperature and screw speed to achieve

optimal briquette quality. The result on the testing procedure showed that briquette

produce by this machine has a high quality can be produced at rate of 10 kilograms per

hour. And then an economic feasibility study was done to show the machine’s capability

in a provincial small business scale.

Automated Briquetting Machine

This study intended to develop an automated briquetting machine for evaluation

purposes that depends on the parameter during briquetting process to produce quality

briquettes.

The designs of this project have been generated from the previous steps of

briquetting machine. It has major parts such as framework, hydraulic system, heating
 28

system, control system and electrical parts. It is a hydraulic press type of briquetting

machine, this prototype used k-type pocket thermocouple for the temperature supplied by

the band heater to the cylindrical mold.

Figure 13. Set up in Verification of the Band Heater

Source: www.researchgate.net

Figure 13 shows that this project have been recorded the pocket thermocouple as

well as built in thermocouple of the band heater for analysis. It uses plus minus five

percent margin of error and the findings has notice a difference between the values of the

readings of the built in thermocouple and pocket thermocouple.

The machine was developed in purpose to experiment or evaluation and not for

large production of briquettes or for employment in urban or rural areas.

Table 2

Cost and requirements of an automated Briquetting Machine

Part experimental price mass production price

Machine fabrication 68,000.00 150,000.00

Heating system 6,224.00 20,000.00
Pressure switch 6,500.00 6,500.00
Pressure gauge 500.00 500.00
Electrical appearances 3,000.00 3,000
 29

Solenoid valve 0.00 8,000.00

Proximity sensors 0.00 2,400.00

Table 2 shows the budget of existing machines that provides a critical information

need to develop the composition of the project or structure of prototype. Ideas gathered

from developers and evaluation of the machines helps the researchers project to estimate

a positive rate of production work. It make the researchers to realize the possible output

of the project and the cost and requirement that might be useful to meet the desire major

objective of prototype.

Hardware Requirements of the Project

Steel

Iron alloy consist of carbon 0.03 percent of them is ingot steel and 2.5 percent of

their mass is cast iron and fluctuating measures of different components. Mostly

Chromium, manganese, molybdenum, nickel, and silicon depending on their uses. Large

volume of carbon create the steel more fluid and cast able.
 30

Figure 14. Steel

Source: https://www.shutterstock.com

Figure 14 shows an image of bundle of circular steel. This steel can be develop by

the consumers how they use it. With the information above, the researchers tend to use

the steel as main material for fabrication of the body and frame of the machine. Because

steel can give enough strength to the structure of the prototype.

Uses of Steel

Steel has wide variety of application when it comes to engineering and

construction material than any other hardware. With its advantageous composition of

alloy and mechanical properties, steel is considered as the most efficient material to be

used in any industrial or commercial construction. Steel has the most tensile strength,

flexibility and it is a low cost material than iron and it said to be that, a construction that

has a tons of steel can give a 40 percent rate of strength. Its applications includes

domestic appliances such as refrigerator, washing machine, and ovens. When it comes to

travel and transport it includes car bodies, engine components, trucks, wheels, and jet

engine components. The potential of the steel gives enough enhancement to a certain

work that needs to be done in a well and great structure. Commonly in a construction

work, steel is incorporated to low and high rise building, modular buildings, tunnels,

stations, coastal, cladding and roofing. It can also be associated to an electrical and

magnetic aspect such as electromagnet, transformer cores, and electromagnetic shield.

Types of Steel

Tool Steel

The main function of this steel is mainly in production where normally producing

or making a tool from metal, wood, plastics and other industrial materials. This steel can
 31

be used in kind of operating condition such that it can operate at elevated or rapidly

changing in temperature, it sometimes concentrated when in an exposed areas. However,

this should not take any hard damage when operating because it can result to dulling

edges or there will be metallurgical changes will happened (G.L Huyett, 2000).

Figure 15. Tool Steel

Source: https://encrypted-tbn0.gstatic.com

As shown in Figure 15, the tool steel is designed to be made into tools. Their

appropriateness originates from their particular hardness, protection from scraped spot

and twisting, and their capacity to hold a cutting edge at hoisted temperatures.

Carbon Steel

From the name itself, this type of steel is commonly came from a carbon and the

structure of this steel is depended only on its carbon content. One of the main examples

of this is diamond, which contain a pure carbon. Carbon is distinguished by its natural

capability to provide hardness and strength of the steel’s structure. Carbon can increase

the maximum strength, toughness, resistance of steel. Furthermore, it also lowers

ductility, and machinability.

 32

Figure 16. Carbon Steel

Source: https://www.onealsteel.com

Figure 16 illustrate an image of carbon steel is made of of silicon, copper and

manganese. Carbon steel is regularly favored in assembling, generation and in tasks

where the steel is for the most part escaped view.

Alloy Steel

Comes from the different mixed metals that composed of different compounds

such as alloy, copper, and aluminum. This is sometimes mainly used in different parts of

cars, pipelines and motors because it is more cheaper than any steel (Capital Steel and

Wire, Inc., 2018).

Figure 17. Alloy Steel

Source: https://www.indiamart.com

The following is a scope of enhanced properties in alloy steels, quality, hardness,

wear protection, erosion protection, hardenability, and hot hardness. To accomplish a

 33

portion of these enhanced properties the metal is needed to conduct heat as shown in

Figure 17.

Stainless Steel

Stainless steel is determined by its natural structure which is composed of 0.10%

chromium with or without any kind of alloy. With its characteristics it can resist

corrosion and it can easily maintain its strength at maximum tolerance.

Figure 18. Stainless Steel

Source: https://tarrisonoutdoor.com

Figure 18 shows an image of a stainless steel. It has a wide range of properties, in

general stainless steels have higher corrosion resistance, higher cryogenic toughness,

higher work hardening rate, higher hot strength, higher ductility and lastly lower

maintenance (AALCO, 2018). This study gives an idea to the researchers to use the

stainless steel for the main material in machine fabrication.

Types of Stainless Steel

Ferritic

Vary from chromium with a less amount of carbon. They are typically constrained

being used to generally thin segments because of absence of strength in welds. Be that as

it may, where welding isn't required they offer an extensive variety of utilizations. They
 34

can't be solidified by warm treatment. High Chromium steels with increments of

Molybdenum can be utilized in very forceful conditions, for example, ocean water.

Ferritic steels are likewise decided for their protection from stretch consumption

breaking. They are not as formable as austenitic tempered.

Austenitic

Is a kind of steel that are the most well-known. Their microstructure is gotten

from the expansion of Nickel, Manganese and Nitrogen. It is indistinguishable structure

from happens in standard steels at significantly higher temperatures. This structure gives

these steels their trademark blend of weldability and formability. Erosion obstruction can

be upgraded by including Chromium, Molybdenum and Nitrogen. They can't be

solidified by warm treatment however have the valuable property of having the capacity

to be work solidified to high quality levels while holding a helpful level of malleability

and sturdiness. Standard austenitic steels are defenseless against stretch consumption

splitting. Higher nickel austenitic steels have expanded protection from stretch

consumption breaking. They are normally non-attractive however ordinarily show some

attractive reaction relying upon the creation and the work solidifying of the steel.

Martensitic

Is found to be similar with ferritic steels in being founded on Chromium yet have

higher Carbon step up as high as 1%. This enables them to be solidified and tempered

much like carbon and low-combination steels. They are utilized where high quality and

direct consumption obstruction is required. They are more typical in long items than in

sheet and plate frame. They have for the most part low weldability and formability.

Duplex
 35

Is a steel that have a microstructure which is around half ferritic and half

austenitic. This gives them a higher quality than either ferritic or austenitic steels. They

are preventive to push erosion splitting. Supposed "lean duplex" steels are planned to

have equivalent erosion protection from standard austenitic steels however with improved

quality and protection from stretch consumption breaking. "Superduplex" steels have

improved quality and protection from all types of consumption contrasted with standard

austenitic steels. They are weldable however require care in determination of welding

consumables and heat input. They have direct formability. They are attractive yet not

even the ferritic, martensitic and PH reviews because of the half austenitic stage.

Precipitation hardening

Steels can have a high quality by including components, such as, Copper,

Niobium and Aluminum to the steel. With appropriate “aging" heat treatment, fine

particles frame in the lattice of the steel which gives it quality. These steels can be

machined that vary on shapes requiring great resistances previously the last maturing

treatment as there is insignificant twisting from the last treatment. This is rather than

traditional solidifying and treating in martensitic steels where distortion is a greater

degree an issue. Corrosion resistance is similar to standard austenitic steels like 1.4301

(304).

Electric Motor

Electrical motor is an electrical machine that transforms the electrical energy into

mechanical energy. Some of electric motor work by using magnetic field and winding

current to produce a force to have a rotation. Electric motors can be run using alternating
 36

current (AC) and Direct current (DC) source. The reverse operation of the electric motor

is the Generator.

Types of Electric Motor

Motors that operate through rotary motion by receiving power when current flows

within a magnetic field are common. However, a wide range of motor types exist,

including ones that operate through linear motion. Motors are broadly classified by the

type of drive power source, the direct current (DC) motors and alternating current (AC)

motors.

DC Motor

Dc motors are mainly used when there is constant or maintainable speed is needed

andi also when the starting condition is moderate. It has different varieties of application

such as blowers, fans, centrifugal pumps, conveyors, elevators and other machines that

need an adjustable speed.

Series Wound

DC series motor is the motor that the armature is connected in series to the field

coil. It is used as traction because it provides high torque compared to other types of dc

motor. Basically, the uses of this are hoist, gates and starter in the automobile.

Shunt Wounds

This is a type of motor where the connection of its field is in parallel or shunt with

armature. Inside of its frame is bundle of wire that has a current independent on the

armature which giving dc shunt motor sufficient speed.

Compound Wound
 37

This type of motor is a dc motor which the field is connected in both series and

shunt (parallel) with the armature. With the arrangement of connecting the series field in

series to the armature with and shunt field connected to parallel with the series.

Permanent Magnet

Dc permanent magnet is a type of motor which used a nonpermanent without

using a coil in the field winding. It has a molded magnet place inside in the metal body.

The supply of this motor is Direct current.

AC Motor

AC motor is a type of electric motor that used Alternating current to run the

motor. Usually AC motor contains two parts stator in the outside and rotor in inside.

Stator having coils powered by alternating current to create a revolving magnetic field

and rotor connected to the output shaft for second revolving magnetic field.

Synchronous Motor

Synchronous motor is the kind of motor which the frequency and speed are

synchronized. It is applicable for driving equipment at sustained speed and high accuracy

positioning device such as robot, instrumentation, machines and process control.

Induction Motor

Induction motor is an AC electric motor which has electromagnetic induction as

of magnetic field in the stator winding electric current creates in the rotor and torque.
 38

Figure 19. Induction Motor

Source: https://www.indiamart.com

Figure 19 shown an image of induction motor is a simple design, high power to

weight ratio, inexpensive, easy to maintain and direct connection to ac power source with

this study the researchers decided to use the induction motor to drive the mechanism of

the machine. The horse power will be identified depending on the computation of electric

motor.

Computation of Electric Motor

In terms of getting the most accurate motor to be used there must be some

calculation that needs to be done in order to have a well-functioning machine and safe

device. An example of four pole motor that operates at 1,800 rpm under no load

condition and 1,725 rpm under load is particularly found in belted application such as

blowers, fans, air handling equipment, compressor and conveyors. However, two pole

motor that operate at a speed of 3,600 rpm unloaded and 3,540 under load is commonly

found in pump application such as sump pumps, water recirculating pumps and

swimming pool pumps. In addition, it can be concluded that the higher rpm the motor

has, the more noise it will produced. It is beneficial to become aware of the different

speed-related sounds motors make. A motor that has speed up to 1,200 rpm unloaded and
 39

1,175 rpm loaded is a six pole motor which sometimes found in air handling equipment,

windows fans, air conditioner and other equipment where slower motor speed produce

less noise at operation. All can come in either totally open, totally enclosed, or

combination models, adding to their versatility.

To satisfy consumers’ desires for quieter motors, manufacturers have developed

eight-pole motors. These operate at 900 rpm (unloaded) and approximately 800 rpm

under load. They are being used in applications where customers expect quieter

operation, such as room air conditioners and outdoor heat pump applications.

Less-common pole configurations include 12-pole motors (600 rpm) that are used

in applications requiring slow speeds, such as washing machines, and 16-pole motors

(450 rpm unloaded), often found in ceiling fans.

The mathematical formula to remember in helping make this calculation is the

number of cycles (Hz) times 60 (for seconds in a minute) times two (for the positive and

negative pulses in the cycle) divided by the number of poles.

Therefore, for a 60-Hz system, the formula would be:

60 x 60 x 2 = 7,200 no-load rpm number of poles.

For a 50-Hz system, the formula would be:

50 x 60 x 2 = 6,000 no-load rpm number of poles.

There are things to vary on selecting an appropriate device for developing a

prototype. The following information provided by this topic, helps the project to get the

formula and make a proper decision on choosing a type of motor in accordance to its

application. With this guide the project tend to use an induction motor to drive the whole

mechanism of the prototype.

 40

Push Button

A push-button actuatable electrical Switch is uncovered. In one exemplification,

the push-button electrical Switch incorporates a body having a first end and a Second

end, an actuator related with the body, a push-button focal point top mounted to the

actuator and reaching out from the principal end of Said body, an electrical switch having

a switch button for enacting the

switch, and a mount

embraced to help a light and

the electrical switch (Patent

No. US 6,590,176 B2,

2003).

Figure 20. Push button

Source. https://patents.google.com/patent/US6590176B2/en

A push buttons are commonly used as triggering device, as the Figure 20

illustrated. Push buttons are also used for motor controlling process with this study the

researchers decide to use a push button device to control the motor in the machine.

Principle of Push Button

Push button is simple single post switches. They contain an arrangement of

contact plates that represent the deciding moment when actuated by somebody. All push
 41

button are made a similar way, what gives them their extraordinary qualities or capacity

is the legend plate and at times the administrator or button head. The legend plate

encompassing the push catch tells the client the motivation behind the control gadget,

regardless of whether it is to turn something on or off or move something up or down,

everything relies upon what the mark is telling the client of the push button to do. In a

few examples, the state of the push button shows its capacity. For instance, a push button

in the state of a mushroom and red in shading illuminates the client that the goal of the

push catch is to fill in as a crisis stop, not at all like a push catch that is just red to

demonstrate stop and additionally green to show begin.

Uses of Push Button

Push button switches have a lot of purposes including calculators, phones and in

different homes appliances. It is responsible for the controls of the machine to perform

different actions just like in the case of application in calculator. This also can be sort in

commercial and industrial usage when it comes to mechanical purposes.

Push button switches have different specified color to modify the action it represent to

avoid failures in operating the machine. Particularly, each color has definite indicating

purpose such as red indicate for stop, green for starting a machine (RS component LTD,

2018).

Circuit Breaker

Circuit breakers give a manual methods for stimulating and deenergizing a circuit

and programmed overcurrent insurance. Not at all like wires, must be supplanted when

they open, an electrical switch can be reset once the overcurrent condition has been

rectified. Driving the handle to the "OFF" position at that point back to the "ON" position
 42

reestablishes the circuit. In the event that a circuit revives upon reset to the "ON"

position, the circuit ought to be checked by a qualified circuit tester (RF Wireless World,

2012).

Principle of Operation

In the accompanying outline, an air conditioner engine is associated through an

electrical switch to a voltage source. At the point when the electrical switch is shut, a

total way for current exists between the voltage source and the engine enabling the engine

to run. Opening the electrical switch breaks the way of current stream and the engine

stops. The electrical switch naturally opens when it detects a blame. After the blame has

been cleared, the breaker can be shut, enabling the engine to work.

Types of Circuit Breaker

Instantaneous Magnetic-trip-only Circuit Breaker

Prompt Attractive excursion just electrical switch. Give hamper however don't

give over-burden security. This sort of electrical switch is regularly utilized in engine

control applications where over-burden assurance is given by an over-burden transfer.

 43

Figure 21. Instantaneous Circuit Breaker

Source: https://www.productinfo.schneider-electric.com

Thermal-Magnetic Circuit Breaker

A thermal magnetic circuit breaker has an outing unit that detects heat to identify

an over-burden and faculties an attractive field created by current to recognize a short

out. This sort of electrical switch trips instantly when a short out happens, yet defers a

suitable measure of time before stumbling in case of an over-burden.

Figure 22. Thermal Circuit Breaker

Source: http://engineering.electrical-equipment.org

The thermal part of the circuit breaker gives a period reaction include, that trips

the circuit breaker sooner for bigger overcurrent yet enables little overloads to endure for

a greater time. This provide short current spikes are being formed when a motor or other

non-resistive load is exchanged on is shown in Figure 22.

Solid-State Circuit Breaker

Solid state circuit breakers and thermal magnetic circuit breakers have

comparative contact systems, yet their trek units are extraordinary. A solid state trip unit
 44

not just decides when to trip the electrical switch, yet in addition has programmable

highlights and enhanced exactness and repeatability.

The mind of a solid state trip unit is a microchip. Alterations on the trek unit set

numerical qualities that the chip utilizes in performing defensive capacities. Current

sensors associated with the excursion unit screen the heap current. The trek unit

ceaselessly looks at this current to trip unit settings. At the point when current surpasses a

preset incentive for the chose time, the outing unit triggers an attractive lock. The

attractive hook opens the breaker's contacts, disengaging the shielded circuit from the

power source (Siemens Technical Education Program, 2014).

Figure 23. Solid-State Circuit Breaker

Source: https://www.researchgate.net

Figure 23 shows an image of different components of solid-state circuit breaker. It

consist of a Zener diode, silicon controlled rectifier, or solid-state devise is linked to feel

when load terminal voltage surpasses a protected value.

Molded Case Circuit Breaker

Siemens molded case switches utilize indistinguishable working component from

the warm attractive and attractive just units. In any case, a preset prompt capacity is plant
 45

introduced to enable the change to trip and secure itself at a high blame current, yet the

switch gives no warm over-burden insurance or short out assurance.

Figure 24. Molded Case Circuit Breaker

Source: https://www.omega.com

Figure 24 shows how molded case circuit breaker looks like. MCCB with

conventional thermal magnetic trip units are being replace by breakers with electronic

trip units. These units provide increase accuracy and repeatability (Galco Industrial

Electronics, 2018). This study gives an idea to the researcher’s to use this kind of circuit

breaker that provides overload protection of the machine.

Agitator

Electric agitator is mainly used as device for maintaining the amount of mixture

entering a process such as mixing, compressing and crushing. This will also help to

control the feed rate and guide to the flow of raw material to the crusher, mixer, and

compressor. The movement of agitator feeder is made from unbalanced motor connected

in the shaft of two motors. Motors are respectively equally align in a right angle of a

frame. With these brief ideas but informative, the researcher wil aim to adopt the

principle operation of feeder agitator to used as one of the main hardware to construct the

prototype (A.V Ramana Rao, 2014).

 46

Figure 25. Rotary Motor Vibrator

Source: https://www.martin-eng.com

As the Figure 26 shown, Electric agitator is a mechanical gadget to produce

vibrations. The agitator is regularly produced by an electric engine with an unequal mass

on its driveshaft. With this study it is concluded that electric agitator is a must for the

briquetting machine. The electric agitator will vibrate the pulverize raw material into the

briquette molder.

Sprocket

A sprocket is a cylinder with teeth around the circumference at either end that

project through perforations in something to move it through a mechanism. The word

itself is mainly regulated to any wheel which radial projections captivate a chain passing

over it. Although sprockets are sometimes referred to as gears, there is a technical

distinction between the two: sprockets interact with chains, whereas gears interact with

other gears (REV Robotics, 2016).

Uses of Sprocket

Motor cycles, cars, bicycles, tracked vehicles, and other machinery uses

sprockets. Sprockets used to transmit rotary motion between two shaft and gears that are
 47

suitable to a track, tape etc. Sprockets are commonly used in bicycle where the pedal

shaft carries the large sprocket wheel. in the early automobiles were also largely driven

by sprocket which be copied from sprockets.

The originator of sprockets have various design and has maximum efficiency.

Flanges cannot be found typically in a sprocket but some sprockets that uses timing belts

have flanges in order to keep the timing belt centered. the power transmission from one

shaft to another where slippage is not permissible, sprockets and chains are used.

Sprocket-wheel being used instead of pulleys and sprocket chain instead of belts.

Sprockets and chain can be run at high speed and some forms are constructed to be

noiseless at even high speed (Robotpark Academy, 2013)

Types of Sprocket

Double Pitch Sprocket

It is a type of sprocket which can be compared to a standard sprocket, except to

numbers of its teeth than a regular one. This is used to accommodate longer distances

between rollers. Its common size are 2040, 2050, 2060, 2080, and 2100 or 2042, 2052,

2062, 2082 and 2102 for larger distance purposes.

 48

Figure 26. Double Pitch Sprockets

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 26 shows an actual image of a double pitch sprockets, this sprocket is

normally classified to a typical sprocket.

Multiple Strand Sprocket

Multi-strand sprockets are used where higher torque and power are needed, or

where two or more items are being powered by a common drive shaft. Available in 40

through 160 chain pitch with plain, finished, taper-lock, or QD style hubs.

Figure 27. Multi Strand Sprockets

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 27 shows an image of multi strand sprockets, it is mainly recommended

when there is need in high efficiency of torque and power.

Taper-Lock Sprocket
 49

Taper-lock sprockets utilize a split through the taper and flange to provide a true

clamp on the shaft. A Taper-Lock bushing is retained to the sprocket with set screws.

They offer flexibility by allowing multiple sized bores for a single bushing size.

Figure 28. Taper-Lock Sprockets

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 28 illustrates the actual image of taper-lock sprockets. This type of

sprocket is mainly used in a wide variety of machine and vehicles. The taper-lock

bushing system helps keep sprocket narrow so the length through dimension is less than

ever before (TB Wood's Altra Industrial Motion, 2018)

Steel Split Sprocket

Steel split sprockets are split through the entire radius for easy installation and

removal. The halves are held together by bolts. This style is available in pitch sizes 40

through 240, and bore diameters of 3/4 through 6 in.

 50

Figure 29. Steel Split Sprocket

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 29 shows a steel split sprocket. This type of sprocket design is

advantageous in many high wear industry applications such as cement and recycling.

Double Single Sprocket

Double single sprockets are used in applications where two or more items are

powered by a common drive shaft. The space between the plates is wider than a multi-

strand sprocket and allows two separate strands of chain to engage without contacting the

other. One strand may exit in a different direction than the other.

Figure 30. Double Single Sprocket

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 30 shows an actual image of a double single sprocket. This kind of

sprocket is designed to run two single strand type roller chains, with this study the

researchers decide to use this type of sprocket for the main parts of the mechanism

system.
 51

Idler Sprocket

Idler sprockets are used where the chain may experience slack due to long

lengths, where there is a non-adjustable drive shaft, or where the chain has been guided

around an obstruction. Using idler sprockets prevents chain whipping and uneven load

distribution.

Figure 31. Idler Sprocket

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 31 shows an image of idler sprocket that used to maintain the tension in a

chain or chain drive system. Idler sprocket pulls against the chain in a constant manner to

keep the chain tight at all times. The size of sprocket use in idler sprocket assembly has

no effect on the performance of the chain drive (Kilchermann, 2018). With this study it is

concluded that an idler sprocket will be equip in the machine to drive the mechanism

system.

Double Plus Sprocket

Double plus sprockets are specifically designed to be used with Double Plus chain

and is in conveyor applications where product is moving at twice the speed of the drive

system powering the conveyor. Benefits include less noise and longer chain life.
 52

Figure 32. Double Plus Sprocket

Source: https://isccompanies.com/parts-distribution/sprockets/

Figure 32 shows a picture of a double plus sprocket, this component has large

center rollers with small rollers on both sides. Chain tension, while conveying objects is

relatively low as it is affected primarily by rolling friction (Tsubakimoto Chain Corp,

1995).

Chain Drive

A chain is commonly used to attach two sprocket where one sprocket is the driver

and the other is the one that will be driven. In addition, the chain is also used to carry out

force and motion to sprocket and this kind of chain is called power transmiasion chains.

Advantage of Chain Drive

Favorable position of chain rolls over most belt drives the chain can't slip on the

sprocket, so the chain and sprocket gives a positive, non-slip drive, i.e. the chain can't slip

on the sprocket on the grounds that the sprocket teeth keep the chain from slipping

(Multimedia D&T Educ., 2018).

Principle of Chain Drive

Chain drives commonly transmit strength starting with one turning shaft to one

more also it keep up a positive speed proportion among driver and driven sprockets. It

will turn a similar way on normal chain drives. In the event that the chain has a
 53

significantly number of pitches, the sprockets have an odd number of teeth (Odesie,

2018).

Types of Chain

Steel Detachable Chain

Is produced using extraordinary hot moved strip steel and is warm treated to

insure high quality and long wear life. It is intended for medium loads and speeds and is

more simple to install and repair (Allied Locke, 2018).

Figure 33. Steel Detachable Chain

Source: https://www.myodesie.com

Figure 33 illustrate an actual image of steel detachable chain, it has commonly

beneficial fiber and fabric composition. Aside from its ingenious design it has its own

durability and toughness.

Pintle Chain

Pintle chain which is particularly used in high speed, about 450 FPM or 137

meters over minutes and heavier loads. Pintle chain is from individual cast links having a

full round barrel end cast regulated with offset side bars. Some application for cotter pins

to hold the pin in place.

It more suitable to use a pintle chain rather than a detachable chain because it can

hold up greater speed and can carry a full load making it valuable in transmitting. It
 54

contains a particular cast links obtain from a full round barrel end cast fundamental with

balance bars.

Figure 34. Pintle Chain

Source: https://www.myodesie.com

Figure 34 shows a normal structure of a pintle chain, this chain is sometimes

called as 400 class pintle chain and it has similarities with detachable chains when it

comes to pitch dimensions so it can be used in both sprockets (Senqcia Corp., 2018).

Leaf Chains

It compose of single link plates and pins and it has a simple design of steel chain.

Leaf chains are more powerful, mostly having higher adjustable strong than roller chains.

In leaf chain it easily attach plates combined with pins. This implies that leaf chains must

be greased up routinely and should just be utilized for low speed applications, for

example, raising and bringing down the forks of a fork lift truck (Multimedia D&T

Educ., 2018)
 55

Figure 35. Leaf Chain

Source: https://www.myodesie.com
Figure 35 shows a picture of a leaf chain which is sometimes called as “Balanced

chain”, this type of chain can be used in several application such as fork lift masts, as a

balancers between head and counter weight in machine tools or for low speed pulling

(Tsubakimoto Chain Corp, 1995).

Silent Chain

Silent chain is consist of two teeth per each with originally assembly of gear

racks, the pivotally is coupled to build a sealed chain. The Pin-connected and flat steel

plates with straight teeth are combine. Silent chains can move in a maximum speed also it

can carry more weight for the same size and its more silent than roller chains

(Encyclopaedia Britannica, 2015).

Figure 36. Silent Chain

Source: https://www.myodesie.com
 56

Figure 36 shows an image of a silent chain with an illustration to its pitch and

connecting pin. Silent chain is contain of stacked rows of flat tooth shaped driving links

that connected with sprockets having compatible tooth spaces (Bearing Service, 2018).

Laminated Metal Chain

an action of a metal chain that is laminated has a thin strips of resilient metal that

lengthen each sides of the link and comply the sides of the sheave face that is ribbed

makes a precise link cession or engagement for variable speed units.

Figure 37. Laminated Metal Chain

Source: https://www.myodesie.com

Figure 37 shows a section of laminated metal chain with an appearance to its parts

which is laminated leaf chain and groove conical sheave. Its sheave chain is made from

thin metal strips sliding and conforming to the grooves rather than an actual tooth or

sprocket engagement of typical roller or silent chain.

Roller Chain

Roller chain contain an advantage for being equally effortless system of

conveyance of mechanical energy. Roller chains are made similar to classic chain

connection framework; that is, a sequence of barrel-shaped rollers attached by joint

(Budimir, 2011).
 57

Figure 38. Roller Chain

Source: https://www.sedis.com

Figure 38 shows an image of roller chain, the main operation of this roller is to

lessen the friction somehow, the rollers have two different functions particularly it is

provided by the same roller. One of these functions is to captivate the sprocket teeth and

thus bring any sliding action to the interior parts of the chain. With this study the

researcher’s decide to use this type of sprocket for the main mechanism and partner of the

sprocket gear.

In line to these ideas the researchers found some useful information regarding to

the working principle of each major part of the prototype. Project will use some modified

type of hardware that will satisfy the needs of the function such as molded case circuit

breaker, agitator, sprocket and chain. It will help the machine to be more efficient and to

have smooth movement.

Solenoid

Solenoid is a type of an electric device that works to convert electrical energy into

a certain mechanical motion. It has a magnetic attraction that provides on transmitting

force. Solenoid has a armature which is the movable part that can be used to transfer

force from the solenoid into useful work.

 58

Solenoid has a varieties application and operating characteristics. There are 5

solenoid configuration first is the clapper solenoid that has armature connected on the

pivot point. The other is horizontal action solenoid which is called as direct action device,

there is also a plunger solenoid that composed of iron cylinder, a bell crank solenoid is

modified as one of the five solenoid configuration which uses lever that is connected in

armature to perform and convert the vertical motion of the armature into horizontal

motion. And the last one is the vertical action solenoid that mechanical assembly but its

operation is to convert vertical action into straight line motion.

Its structure is mainly composed of wrapped wire and the electrical passing

through it, causing the armature be pulled toward the coil. Solenoid can be used and

attach to a certain device to perform a specific movement or action. There are two

primary characteristics of solenoid and one of these is the amount of voltage applied to it

and the amount of current allowed to pass through the coil.

Figure 39. Solenoid Lock

Source: https://www.trossenrobotics.com
 59

Figure 39 shows an image of a solenoid lock, from the statement above this give

an idea to the researchers to use this type of solenoid for the locking of lifting and base of

the machine in which the compressor can mold the pulverized charcoal.

Magnetic Contactor

One of the most commonly used device in electrical industry is magnetic

contactor, which function is to balance electrical frequency that comes from any power

supply. Contactors are sometimes compared to a circuit breaker but its not, there maybe

some similarities in function but its still not the same. Magnetic contactors are design to

be detachable from motor to maintain the operators safety on working.

To elaborate the process inside the contactors, Albers (2018) stated that when

there is an electricity passing through the contactor, a magnetic field will be created and

that field will force the iron core to move to the coil and produces an electrical arc.

Contactor can be operated in physical manner to deactivate it, with this action the spring

inside the contactor will push the core away from the coil making it cut the connection.

Figure 40. Magnetic Contactor

Source: https://m.made-in-china.com
 60

Figure 40 shows an image of a magnetic contactor, Magnetic contactors is design

to be straight connected to high- current load devices from the discussion this give an

idea to the researchers to use this magnetic contactor for the safety of workers to operate

the machine.

Thermal Overload Relay

This device is one of the protective devices which is particularly used in many

application for main circuit. Thermal overload relay can give an effective protection to a

circuit in times of any trouble or circuit failures. This can be paired together with

contactors to be more efficient and have an effective and safe circuit.

Figure 41. Overload Relay

Source: https://uk.rs-online.com

Figure 41 illustrate an image of a thermal overload relay, overload relay is

electrical device used to protect the motor from overload, high current and phase failure.

With this study the researchers decide to use this type of overload relay as one of the

main parts to run safety the AC motor.

 61

Relay

Relay is a type of electromechanical switch which contain a different parts such

as electromagnet, spring, armature and a set of electrical contacts. A certain work or

mechanism can be perfectly done using this kind of hardware for switching either on or

off using its electrical contacts. This device is appropriate when there is an electrical

operation between controls and control circuit, or mainly when there is a multiple works

should be done in one signal.

Figure 42. Relay

Source: https://uk.rs-online.com

Figure 42 shows an image of a relay, relay is a electromechanically or

electronically switches that open and close the circuits. This give an idea to the

researchers to use this type of relay for the control of ac motor and agitator in the

machine..

Sensor

Sensor is particularly helpful in controlling a certain mechanical motion with its

power to detect and respond quickly to an input. These input is determine as light,

motion, moisture, pressure, or any environmental phenomena that can be detected. The
 62

output of sensor can seen to monitoring area or wherever the output is transmitted for

reading and processing.

Capacitance Proximity Switch

This type of sensor is gives an advantageous effect to its user because of its

application and affordable cost. Capacitance proximity sensors is mainly used in a dry,

free flowing and this device requires solid state output.

This sensor will allow the user to know the electrical effect of the objects around

the sensor inside the hopper, vessel or any container that solid material can be poured

into. To be able to analyze the effect of surrounding on the material, a radio frequency is

applied. This sensor will operate when detecting a contact passing through the sensing

region of the sensor.

Proximity is the main sensor to be used in order to detect a presence or moving of

a certain powder or bulk solids. Therefore this only used when the material to be used is

dry or free flowing. This type of sensor is really applicable to any applications that will

fit its physical structure like in a machine that has a hopper section or bins.

Figure 43. Proximity Sensor

Source: https://m.indiamart.com
 63

Figure 43 illustrate an image of a capacitance proximity sensor, From the

discussion above this give an idea to the researchers to use this type of sensor it will be

equip in the machine for the alarm of the hopper when the pulverize charcoal is

suffiecient.
 64

Evaluation System

The evaluation process will be conducted through a survey using a qualitative

method in determining the performance of the project. The survey is based on the TUP

evaluation system provided with a set of criteria as follows:

Functionality pertains to ease of operation, provision of comfort and

convenience.

Aesthetics of the project refers to color appeal, attractiveness, and appropriateness

of the design.

Durability of the project refers accordingly to the quality of materials, quality of

workmanship, and quality of design.

Economy is evaluated in terms of material needed, time labor spent, and machine

required.

Safety pertain the absence of toxins and hazardous materials, absent of sharp

edges, and provision of protective devices.

Saleability / Marketability concerns the consumer’s demand, accessibility of the

finished product and price affordability.

 65

Conceptual Model of the Study

On the basis of the foregoing concepts, theories and findings of related literature,

studies presented and insights from them, a conceptual model is developed as shown in

figure 39.

Figure 44. The Conceptual Model of the Study

Figure 44 shows a conceptual model of the study which illustrates a chronological

order of topics in knowledge requirement from charcoal to evaluation and hardware

requirements containing different materials needed and will be provided on constructing

the prototype, such as steel, pushbutton, circuit breaker, agitator, and sprocket
 66

respectively. Design, development, testing and evaluation are included in the process of

the project which are needed in order to accomplish and modify the machine. The final

output will be the projects prototype wherein performance is subjected and evaluated in

terms of functionality, workability, durability, aesthetic, economy, salability and safety.

 67

OPERATIONAL DEFINITION OF TERMS

For thorough understanding of the terminologies, the following terms are defined

as it used in the study.

Eco Briquetting machine is a prototype that will be made to accomplish the

objective and put out the problems of older machines on briquetting process in terms of

time, speed, and cost.

Carbon is a basic building block of a charcoal and when at high temperature it

binds with oxygen to form carbon monoxide or dioxide.

Ground pit method is a process of excavation of ground in order to study or

sample the composition and structure of charcoal.

Briquettes is a compressed raw material and the main product of the proposed

project.

Wood charring is a technique on getting the resulting residue of wood as raw

material in making a charcoal.

Lump charcoal is a type of charcoal and it is a product from burned pieces of

wood.

Carbonization is a process of converting a organic material into a carbon by

heating or burning it.

Porosity is a characteristic of a charcoal and one of the main reason to the

capability of charcoal’s absorption.

Pyrolysis is a thermochemical treatment or process of exposing the raw material

at high temperature which can be applied to any organic material.

 68

Kiln is a traditional chamber which is used as equipment for burning wood in

order to produce a certain product such as charcoal.

Briquetting is a process of compressing a raw material in order to have a

charcoal product. It is also associated with the main operation of the project’s prototype.

Stainless steel is a corrosion resistance and used in many products, storage,

backplashes and cooking utensils. It will be used as one of the main material for

fabricating the machine

Electric motor is a equipment that converts electrical energy to mechanical

energy. It will be used by the reseachers to run the mechanism system of the machine

Push button is a perfunctory switch that is used as a trigger device for motor

controlling process. Four Push button is what the reseachers is planning to use it

Circuit breaker is an automatic device used to stop massive amount current to

flow in the circuit. Molded case circuit breaker is that the researcher will be using

Agitator is a device that producing shaking motion on an equipment that the

researchers will be using.

Sprocket is a circular form material that has a teeth on the edge that suitable to

the holes of chain to make a synchronized movement. Sprocket will be equip in the

machine for the main mechanism system

Chain drive is a mechanical system used to transfer mechanical energy to one

place to another. Chain drive it will be used in the machine for the mechanism system

and to run the sprocket gear.

 69

Chapter 3

RESEARCH METHODOLOGY

This chapter presents the project design development, operation and testing

procedure and the evaluation procedure.

Project Design

The briquetting machine is designed to help the small scale organization like

Tree’s a life in producing charcoal from agricultural waste specially water hyacinth. The

machine is equipped with a fabricated hopper moving onward and backward motion to

fill the molder with pulverized raw material, a cylinder that moves up and down to lift

briquette charcoal and a compressor that will compress the pulverized raw material to

mold a briquette by a single induction motor using a chain drive and sprocket system.

Another motor, specifically agitator motor, is mounted under the steel plate hopper to

vibrate the pulverized charcoal for falling into a molder. A control panel is mounted on

the right side of machine for connection. Lastly, limit switches are installed in the

maintenance door for a safety feature.

Hopper and Compressing

ejecting section section
 70

Control section Lifting section

Figure 45. Isometric View of the Prototype

The proposed machine has four major sections, hopper and ejecting section,

control section, compressing section, and lifting section as shown in figure 45. Hopper

and ejecting section contains a pulverized raw material to fill the briquette cylinder

molder and compressing it by compressing section. The compressing section provides the

compacting process that driven by mechanical presser. Afterwards, lifting section

perform its function to lift the briquetted charcoal and then ejecting it in a synchronized

manner.

Control Section Hopper/ Ejecting Compressing

 Push Button / Section Section
Indicator Light  Stainless  Steel
Button Steel Hopper cylinder
 Emergency  Movable  Electrical
Button hopper Motor
 Breaker mechanically  Sprocket
controlled  Chain
 Contactor
 vibrator
 Alarm

Lifting
section

 Stainless
steel
 Steel
cylinder
 Solenoid
lock
 Electrical
Motor
 Sprocket
 Chain
 71

Figure 46. Block Diagram of the Eco briquetting Machine

Figure 46 shows the block diagram of the project with the process and materials

required for each section. The control section contains a panel board, breaker, and

contactor to supply enough energy to the machine. It also has push buttons, and

emergency stop to manage the overall function of the machine. Moreover, stainless steel

will be used as the material for hopper section to develop its proper structure to hold the

pulverized charcoal. Afterwards, compressing section will mechanically compress the

pulverized charcoal using the 2 hp motor. Then the lifting section will deliver the

briquetted charcoal to hopper and solenoid lock that locks the lifting section in order for

the hopper to eject the briquetted charcoal and releases after ejecting to fill for another

briquette.

Project Development

The following are the essentials parts of the eco - briquetting machine.

1. Machine Frame Assembly

a. Base

b. Cover

2. Control Section

a. Push Button / Indicator Light Button

b. Emergency Button

c. Relay

d. Breaker

e. Contactor
 72

3. Hopper and Ejecting Section

a. Fabricated Stainless Steel Rectangular Hopper

b. Bearing

c. Steel separator

4. Compressing section

a. Stainless Steel cylinder

b. Steel plate

c. Bearings

d. Round bar

5. Lifting Section

a. Stainless Steel Plate

b. Solenoid lock

c. Limit switch

Fabrication Procedure

A. Machine frame Assembly

 73

Figure 47. Body and Frame Assembly

1. Body and Frame Assembly

The body and frame is made of stainless steel plate. The center side part of two

angular bar is a 2x2 angular bar where the ac motor is place.

a) Prepare 3 length of 2x2 angular steel bar.

b) Cut the angular steel bar with the following dimension

i. seven pieces of 60 cm angular bar for width of the body

ii. six pieces of 120 cm angular bar for length of the body

iii. four pieces of 130 cm angular bar for height of the body

iv. four pieces of 30 cm angular bar for the brace of the molder

v. four pieces of 15 cm angular bar for the brace of the molder

vi. two pieces of 40 cm angular bar for brace of the controls

vii. one pieces of 30 cm angular bar for brace of the controls

c) Weld the four 130 cm, two 60 cm, two 120 cm angular bar to form the

rectangular body

d) Weld the two 60 cm angular bar at the height of 100 cm from grounding.

e) Weld the two 120 cm angular bar at the height of 100 cm and width both

side by 15 cm.

f) Weld the two 120 cm and one 60 cm at the top of the body.

g) Weld the four 30 cm and 15 cm angular bar and placed together inside the

body to support the molder base

h) Weld the two 40 cm and one 30 cm and placed

 74

i) Weld the two 60 cm angular bar place at the center bottom of the machine

j) Prepare 70 x 80 cm flat bar steel

k) Cut the stainless flat bar with the following dimensions:

i. one 50 x 60 cm flat bar , weld and drill to the center bottom of

body

ii. one 6 x 15 cm flat bar, drill 2 holes and bolt & nut to the flat bar

iii. one 6 x 20 cm flat bar, drill 2 holes and bolt & nut to the flat bar

l) Place the motor and bolt & nut to the center bottom of stainless flat bar

inside the base

2. Control Section

Figure 48. Control Section

a) Prepare the stainless steel plate

b) Cut the stainless steel plate with the following dimension

i. two 20 x 15 cm steel plate for both side of the control box

ii. two 30 x 20 cm steel plate for front and back of the control box
 75

iii. two 30x 15 cm steel plate for top and bottom of the control box

c) Weld the two 30 x 15 cm, one 30 x 20 cm and one 20 x 15 cm

d) Layout the circuit breaker to the center of 20 x 15 cm stainless plate and

drill and cut.

e) Layout the pushbuttons, indicator lamp and buzzer at the center of 30 x 20

cm and drill

f) Weld the 20 x 15 steel plate at the side of the control box

g) Drill 30 x 20 cm steel plate and connect the hinges to the left side of the

control box

3. Hoper and ejecting Section

Figure 49. Hopper Section

a) Prepare the stainless steel plate

b) Cut the stainless steel plate with the following dimensions:

i. four 20 x 15 cm steel plate for the front and back of the hopper

ii. three 50 x 15 cm steel plate for the both side of the hopper
 76

iii. one 50 x 40 cm steel plate for the bottom of the hopper

c) Weld the four 20 x 15 cm and three 50 x 15 cm steel plate to form two

rectangular hopper

d) Weld the one 50 x 40 cm steel plate at the bottom slant of the hopper

e) Prepare 2x2 stainless steel bar and cut with the following dimension:

i. one 70 cm stainless steel bar for the brace and mechanism of the

hopper

ii. two 20 cm stainless steel bar for the brace of the hopper

iii. one 50 cm stainless steel bar for the brace of the hopper

f) Weld the one 70 cm, two 20 cm, and one 50 cm steel bar and place at the

bottom of the first hopper

g) Prepare the one 80 cm circular round bar with the diameter of 15 mm and

four 40 cm with the diameter of 10 mm

h) Install the sprocket inside the one 80 cm round bar and weld the two 40

cm on the both side

i) Install the bearings in two 40 cm round bar on the available side and the

two 40 cm round bar both side

j) Connect the four 40 cm round bar by bolt & nut to build the mechanism of

the hopper
 77

4. Compressing Section

Figure 50. Compressing Section

The compressing will be constructed with circular stainless round bar and a

flat bar steel.

a) Prepare the 2 length of stainless circular round bar with the diameter of 20

mm

b) Cut the circular round bar with the following dimensions:

i. Four pieces of 150 cm stainless circular round bar for stand and

mechanism of the compressing section.

ii. two pieces of 75 cm stainless circular round bar for the stand of the

body

iii. eleven pieces of 10 cm circular round bar for the compressing

section
 78

c) Prepare the stainless steel flat bar and cut with the following dimensions:

i. Two 50 x 20 cm steel flat bar for the top and mechanism of

compressing

ii. Four 10 x 5 cm of steel flat bar for both side of 50 x 20 cm steel

flat bar and circular flat bar

iii. Four 50 x 3 cm of steel flat bar for the mechanism of machine

iv. Build two circular flat bar with the diameter of 60 cm

v. Two 10 x 5 steel flat bar for the brace

vi. Two 30 x 5 steel flat bar for the brace

d) Drill two holes both side of the 50 x 20 cm stainless steel flat bar

e) Weld the four 150 cm circular round bar at the top of the first 50 x 20 cm

flat bar and put four bearing in the holes of second 50 x 20 cm and insert

in the circular round bar.

f) Weld the eleven pieces of 10 cm to the center of the second 50 x 20 cm

steel flat bar

g) Drill the center of the four 10 x 5 steel flat bar and placed the two both

side of the 50 x 20 cm flat bar and connect the four 50 x 3 cm flat bar to

the two 10 x 5 cm flat bar

h) Weld the two 10 x 5 cm and two 30 x 3 cm steel flat bar to form the 90

degree and weld to the right side of 50 x 20 cm flat bar

i) Prepare the 60 cm of circular round bar with the diameter of 10mm and

place the sprocket gear at right side of circular bar and insert the two

bearings both side for the mechanism of the machine

 79

j) Weld the two circular steel flat bar to the 60 cm circular round bar both

side and connect the two last 10 x 5 flat bar to the both side of two circular

flat bar.

k) Prepare the 2x2 stainless steel bar and cut by 15mm and weld it in the

center of four 150 mm circular round bar for the brace of the sprocket

mechanism

5. Lifting Section

Figure 51. Lifting Section

a) Prepare the stainless steel flat bar

b) Cut the stainless steel flat bar with the following dimensions:

i. One 50 x 40 cm steel flat bar for the base of the lifter

ii. Two 50 x 25 cm steel flat bar for the holder and the lifter

iii. Two 10 x 5 cm steel flat bar for the brace of the gear
 80

c) Prepare the 20mm diameter of stainless round bar and cut with following

dimensions:

i. eleven pieces of 10mm length of round bar for the lifter

ii. two pieces of 20 mm length of round bar

d) Prepare the 10mm diameter stainless round bar and cut two pieces with

the length of 30 mm

e) Weld the eleven pieces of 10mm round bar to the first 50 x 25 cm flat bar

f) Weld the two 30 mm round bar in the second 50 x 25 flat bar and connect

the two 50 x 25 flat bar with the solenoid lock

g) Weld the 20 mm length round bar to the 50 x 40 cm flat bar and weld the

two 10 x 5 cm flat bar at the top both side of the base

h) Drill and install the gear with bolt & nut and place to the 10 x 5 flat bar

B. Electrical Assembly

The electrical Assembly shows the wiring diagram of components

of the briquetting machine. Figure 52 to 54 shows the schematic diagram

needed
 81

Figure 52. Single Phase Motor and Electric Agitator Diagram

Figure 52 illustrates a diagram of single phase motor and electric agitator. The

power circuit diagram for the motor and the agitator motor.

Figure 53. Motor Control Diagram and Agitator Relay Diagram

The control circuit of the motor, as shown in Figure 53, shows a start- stop direct

on line wiring diagram. The control composed of emergency stop button, normally open
 82

limit switch maintenance door and normally close contact relay 1 in series with stop

button and overload relay. The emergency stop that stops the system in case of

emergency, a maintenance door that stops the system when the door is open and the relay

1 that stops the system when the solenoid lock fails to function to make the system safe

from damaging itself. Relay 2 serves as a control circuit for the motor agitator.

Figure 54. Limit Switch, Relay, and Solenoid lock Diagram

Figure 54 shows an image of limit switch, relay and solenoid lock diagram. Limit

switch and limit switch 3 are in series with relay 1, these diagram serves as a safety

purposes for the machine in case when the solenoid lock in the lifting section fails to do

its function, the system will stop in order for the compressing and the lifting section will

not collide in result in damaging the machine. The limit switch 4 serves as a stop for

solenoid lock to be press by the hopper to fill for another briquette. LS5 is in series with
 83

buzzer will alarm and illustrates when the pulverized charcoal in the hopper is not

sufficient to fill the molder.

Operation and Testing Procedure

Operation Procedure

1. Put the pulverized charcoal to the hopper

2. Check if the maintenance door is close

3. Energized the Motor Agitator

4. Press the start button

5. Observe the motor operates the system

6. Check if all the cylinder is filled with pulverized charcoal

7. Observe if the compressor works properly

8. Observe if the lifted briquetted charcoal is completely whole

9. Observe if charcoal has uneven size

Testing Procedure

Speed Testing

This test will be done in order to determine the output that the machine can finish

per batch from traditional briquetting and designed eco briquetting machine.

1. Prepare the pulverized charcoal to be used for testing

2. Start the machine and the manual machine briquette

3. Time the output that the machine can finish per batch.

4. Record the data

5. Fill the data on the table below

 84

Table 3

Minutes per batch

________________________________________________________________
Trial 1 (min. /batch) trial 2 (min. /batch) ave. % difference
________________________________________________________________
Traditional machine
Designed machine
________________________________________________________________
Output Stability Testing

This test will be done in order to determine the output that the machine can finish

per hour from traditional briquetting and designed eco briquetting machine.

1. Prepare the pulverized charcoal to be used for testing

2. Start the machine and the manual machine briquette

3. Count the output that the machine can finish per hour.

4. Record the data

5. Fill the data on the table below

Table 4

Output per hour

________________________________________________________________
Traditional Machine Designed Machine
________________________________________________________________
One hour
Two hours
Three hours
Average
________________________________________________________________

Burning Efficiency test

This test will be done in order to determine the combustion time of the briquette

(time that a briquetted charcoal will be fully consumed when burned) made from
 85

traditional briquetting and the designed eco briquetting machine, which of them burned

longer.

1. Prepare the briquetted charcoal produced by the designed machine and

traditional machine

2. Start combusting both briquetted charcoal

3. Record combusting time when it is fully consumed

4. Fill the data on the table below

Table 5

Burning Time
________________________________________________________________
Trial 1 (hr. /s /pc.) Trial 2 (hr./s /pc.) ave. % difference

________________________________________________________________

Traditional machine
Designed machine
________________________________________________________________

Evaluation Procedure

The performance of the eco briquetting machine will be evaluated using the TUP

instrument. 20 respondents will rate the project composed of (3) workers from tree’s a

life, five (5) faculty member, two (2) mechanical engineer, five (5) electrical experts and

five (5) electrical students. Prior to the evaluation, the project will be demonstrated in

front of the said evaluator. The parts and function will be explained before giving the

actual instrument. After the presentation, the instrument will be distributed, collected,

tabulated and computed for the mean score. Suggestions, feedback, and recommendations

will be noted by the proponents for additional improvement of the system.

 86

Table 6

Descriptive Interpretation of the Mean

________________________________________________________________
Numerical Rating Descriptive Interpretation
________________________________________________________________

4.51- 5.00 Excellent

3.51- 4.50 Very Good
2.51- 3.50 Good
1.51- 2.50 Fair
1.00- 1.50 Poor
________________________________________________________________

The mean score will be interpreted using the descriptive interpretation percentage

in Table 6.
 87

References
A.V Ramana Rao, e. a. (2014, April). Selection of Vibratory Motors for Vibrating Feeder
by Analytical Approach for Material Handling Plants. International Journal of
Engineering Trends and Technology (IJETT), 6. Retrieved October 2018, from
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AALCO. (2018). Retrieved October 2018, from AALCO:
http://www.aalco.co.uk/datasheets/Stainless-Steel_St-St-Introduction_61.ashx
Allied Locke. (2018). Allied-Locke Industries. Steel Detachable Chains On Allied-Locke
Industries. Retrieved September 2018, from
https://chains.alliedlocke.com/viewitems/agricultural-chains/steel-detachable-
chains
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Appendix A

Gantt chart of Activities

MAJOR IMPLEMENTING SCHEDULE

ACTIVITIE November December January February March
S
1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 2
0 1 2 3 4 5 6 7 8 9 0
Planning,
Research
and
Designing

Canvassing
Of
Materials

Project
Fabrication

Mechanical
Assembly

Electrical
Assembly

Testing
And
Evaluation
 92

Appendix B

Development of an Eco-Briquetting Machine

EVALUATION SHEET

Instruction: Please evaluate the prototype by using the given scale and placing a
checkmark ( ) under the corresponding numerical rating.
Numerical Rating Equivalent
5 Excellent
4 Very Good
3 Good
2 Fair
1 Poor
INDICATORS 5 4 3 2 1
A. Functionality
1. Ease of Operation
2. Provision for Comfort and Convenience
3. User-friendliness
B. Aesthetics
1. Color appeal
2. Attractiveness of design
3. Appropriateness of size
C. Workability
1. Availability of materials
2. Availability of technical expertise
3. Availability of tools and machines
D. Durability
1. Quality of materials
2. Quality of workmanship
3. Quality of Design
E. Economy
1. Economy in terms of materials needed
2. Economy in terms of time/labor spent
3. Economy in terms of machine
F. Safety
1. Absence of toxic/hazardous materials
2. Absence of sharp edges
3. Provision for protection devices
G. Salability / Marketability
1. Presence of market demand
2. Accessibility to finished products
3. Competitiveness to price
 93

Summary:
a. Functionality …………………………….. ___
b. Aesthetics …………………………….. ___
c. Workability …………………………….. ___
d. Durability …………………………….. ___
e. Economy …………………………….. ___
f. Safety …………………………….. ___
g. Salability …………………………….. ___
 94

Development Cost

Qty. Unit Specifications Unit Price Total Price

5 Meters Stainless steel 3390 3390
1 Length Angular bar 2081 2081
2”x2”x 8mm
1 Meter Round 1330 1330
stainless steel
pipe
6 Meters Round bar 4125 4125
stainless steel
¾” x 6m
1 Length Flat bar steel 4,770 4770
8”x8’x 6mm
1 Pcs Induction 4000 4000
motor
1 Pcs Circuit breaker 350 350
20A w/ case
4 Pcs Pushbutton 50 200
IN.025mm
1 Pcs Timer HH3nc 500 500
220v
1 Pcs Relay 5a 225 225
1 Pcs Contactor 400 400
wlxlm d09.10
1 Pcs Terminal block 80 80
12p 25A
6 Pcs Pilot lamp 70 420
3 Meters Royal cord 90 270
3.5mm
1 Pcs Heavy duty 40 40
plug
20 Meters Wire thhn 20 400
3.5mm
1 Pack Wye connector 108 108
2 Pcs Limit switch 70 140
1 Pcs Emergency 125 125
stop
1 Pcs Over load relay 400 400
6 Pcs Sprocket 380 2280
3 box Steel 240 720
motorcycle
chain
10 pcs Bearing 65 650
 95

30 Pcs Bolt and nut 0.8 24

1 Pcs Solenoid lock 350 350
1 Pcs Liquid metal 52.75 52.75
polish
TOTAL AMOUNT: Php 26657.75
 96

Appendix C

TOTAL BUDGETARY REQUIREMENTS

PARTICULARS AMOUNT (Php)

1. Personal Services (PS)
1.1 Contractual Labor
1.1.1 Machining 20,000.00
1.1.2 Fabrication 30,000.00
Total Personal Service 50,000.00

2. Maintenance and Other Operating Expenses

2.1 Travel Expenses 1,000.00
2.2 Materials and Supplies 26,657.75
Total Maintenance and Other Operating Expenses 27,657.75

Total Budget 77,657.75

 97

RESEARCHER’S PROFILE

PERSONAL INFORMATION

NAME: DANABAR, DEMIE JAY V.

BIRTHDAY: MAY, 5 1998

BIRTHPLACE: QUEZON CITY

AGE: 19 YEARS OLD

RELIGION: ROMAN CATHOLIC

CIVIL STATUS: SINGLE

FATHER’S NAME: DANABAR, DANTE

MOTHER’S NAME: DANABAR, JANETH

EDUCATIONAL BACKGROUND:

TERTIARY: TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: BACHELOR OF TECHNOLOGY MAJOR IN

ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2015-2019)

SECONDARY: BATASAN HILLS NATIONAL HIGH SCHOOL

S.Y. (2011-2015)
 98

RESEARCHER’S PROFILE

PERSONAL INFORMATION

NAME: GARACHICO, JUSTENE S.

BIRTHDAY: JULY 19, 1997

BIRTHPLACE: PUNTA, LOOC, ROMBLON

AGE: 21 YEARS OLD

RELIGION: ROMAN CATHOLIC

CIVIL STATUS: SINGLE

FATHER’S NAME: GARACHICO, JUSTINIANO M.

MOTHER’S NAME: GARACHICO, AMADA S.

EDUCATIONAL BACKGROUND:

TERTIARY: TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: BACHELOR OF TECHNOLOGY MAJOR IN

ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2015-2019)

SECONDARY: LOOC NATIONAL HIGH SCHOOL

S.Y. (2010-2014)
 99

RESEARCHER’S PROFILE

PERSONAL INFORMATION

NAME: REYES, RAMIL BARON Q. JR.

BIRTHDAY: MARCH 8, 1999

BIRTHPLACE: MANILA CITY

AGE: 19 YEARS OLD

RELIGION: BORN AGAIN

CIVIL STATUS: SINGLE

FATHER’S NAME: REYES, RAMIL R. SR.

MOTHER’S NAME: REYES, MA.LEONORA Q.

EDUCATIONAL BACKGROUND:

TERTIARY: TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: BACHELOR OF TECHNOLOGY MAJOR IN

ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2015-2019)

SECONDARY: MANUEL G. ARAULLO HIGH SCHOOL

S.Y. (2011-2015)
 100

RESEARCHER’S PROFILE

PERSONAL INFORMATION

NAME: VIVERO, JEFFREY A.

BIRTHDAY: DECEMBER 14, 1989

BIRTHPLACE: VALENZUELA

AGE: 28 YEARS OLD

RELIGION: BORN AGAIN

CIVIL STATUS: SINGLE

FATHER’S NAME: VIVERO, JOHNNY C. SR.

MOTHER’S NAME: VIVERO, FLORIDA C.

EDUCATIONAL BACKGROUND:

TERTIARY: TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: BACHELOR OF TECHNOLOGY MAJOR IN

ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2015-2019)

SECONDARY: GEN. TRIBORCIO DELEON NATIONAL HIGH SCHOOL

S.Y. (2002-2006)
 101

RESEARCHER’S PROFILE

PERSONAL INFORMATION

NAME: SARMIENTO, JONATHAN S.

BIRTHDAY: DECEMBER 15, 1991

BIRTHPLACE: QUEZON CITY

AGE: 26 YEARS OLD

RELIGION: ROMAN CATHOLIC

CIVIL STATUS: SINGLE

FATHER’S NAME: SARMIENTO, JAIME V.

MOTHER’S NAME: SARMIENTO, ZENAIDA P.

EDUCATIONAL BACKGROUND:

TERTIARY: TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: BACHELOR OF TECHNOLOGY MAJOR IN

ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2018-2019)

TECHNOLOGICAL UNIVERSITY OF THE PHIIPPINES

COURSE: ELECTRICAL ENGINEERING TECHNOLOGY

S.Y. (2011-2014)

SECONDARY: JUSTICE CECILIA MUNOZ PALMA HIGH SCHOOL

S.Y. (2007-2011)