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Gasifier for crumb rubber drying. Ideal Crumb Rubber Factory Sreekrishnapuram, Mannarkkad. Present Scenario in operation. Optimisation of working results Increase in Productivity. Reduction in cost of Production. Reduction in waste. Cost components Raw Material cost - Not controllable

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gasifier for crumb rubber drying

Gasifier for crumb rubber drying

Ideal Crumb Rubber Factory

Sreekrishnapuram, Mannarkkad

present scenario in operation
Present Scenario in operation

Optimisation of working results

  • Increase in Productivity.
  • Reduction in cost of Production.
  • Reduction in waste.

Cost components

  • Raw Material cost - Not controllable
  • Cost of drying the rubber
  • Cost of Electrical energy
  • Other costs of wages, Maintenance etc.
drier cost component
Type of drier : Continuous trolley type tunnel dryer

Fuel Consumption : 22 lts / Hr of HSD or SKO

Specific fuel consumption : 36.6 Lts per Ton of crumb rubber

Average fuel cost : Rs. 18 per Ltr

Cost of operation of dryer : Rs.396 /hour of operation

Rs.659/- per ton of rubber dried

Fuel cost reduction in the drier was the primary

objective to reduce the overall cost of final product

Drier Cost Component
process towards cost reduction
Process towards cost reduction
  • Non conventional energy ?
  • Consultant in the area?
  • Seminars by MNES / Agencies
  • Manufacturers of gasifier
  • Site Visits
  • Technology provider
analysis of technology
Analysis of technology
  • Economy of operation.
  • Safety of installation as well as people working.
  • Ease of Maintenance.
  • Trouble free performance.
  • Continuous operation.
  • Lower down time for maintenance.
  • Low emission of tar or any other pollutants.

After visit to IISc, Bangalore and various installations the

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

positive features we noticed
Positive features we noticed
  • Flame trap to arrest flame flash back.
  • PP valves to ensure long and trouble free operation.
  • Brick lined inner and SS construction.
  • Servicing platforms to facilitate easy servicing.
  • Audiovisual alarms for critical parameters.
  • Oxygen sensor-Offline to ensure safety of oxygen ingress.
  • Screw conveyor for ash removal & Biomass flexibility.
  • Technological back up from the premier institution

Indian Institute of Science,Bangalore

maintenance of the gasifier
Maintenance of the gasifier

Total hours of operation : 5000 Hours

Total No. of stoppages : 6

Continuous operation : Up to 1250 hours

Replaced components : Air nozzles

Cost of maintenance : Rs.28,300/- till date

Post supply additions : Flame failure system

Timers for screw operation

Post supply replacements : Valve – 1 No.

Cost of maintenance : Rs. 5=66 per hour

economics of operation
Economics of operation

Operation of the gasifier : 5000 Hours (98% up time)

Average cost of biomass : Rs. 2=50 per kg

Biomass consumed : 347279 kgs

Fuel oil replaced : 109846 lts

HSD Cost (W/O Gasifier) : Rs. 19,77,228

Biomass Cost : Rs. 8,68,198

Additional power cost : Rs. 79,888

Net Saving : Rs. 10,29,143

Savings as percentage : 52%