1. Gasifier for crumb rubber drying
Ideal Crumb Rubber Factory
Sreekrishnapuram, Mannarkkad

2. 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.

3. Drier Cost Component Fuel cost reduction in the drier was the primary
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

4. Process towards cost reduction
Non conventional energy ?
Consultant in the area?
Seminars by MNES / Agencies
Manufacturers of gasifier
Site Visits
Technology provider

5. 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.

6. 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

7. 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

8. Economics of operation
Operation of the gasifier : 5000 Hours (98% up time)
Average cost of biomass : Rs. 2=50 per kg
Biomass consumed : kgs
Fuel oil replaced : lts
HSD Cost (W/O Gasifier) : Rs. 19,77,228
Biomass Cost : Rs. 8,68,198
Additional power cost : Rs ,888
Net Saving : Rs. 10,29,143
Savings as percentage : 52%