It is seen that large quantities of agricultural crop residues are being wasted. A major disadvantage of most recyclable waste is their bulk i.e. it requires a large space for accommodation.
It has been observed by bio-scientists that if the waste is burnt, this affects the soil microflora, results in loss of nitrogen and organic matter. Most bulky residues need some type of pre-incorporated physical processing or shredding to facilitate their rapid decomposition and mixing with the soil.
It has been an established fact that finer particles (4 to 5 cm) decompose faster as compared to large particles.
Shredder is ideal for disposal of course leaves, garden and agricultural wastes. Such as twinges, small branches, flower stalks straw, tree pruning etc. This scientific way returns the nutrients back to the soil in natural ways. Therefore the efforts must be concentrated towards effective utilization of all the wastes.Serious efforts in this direction provide rich dividends to the farmers as well as solve the disposal problems, minimize pollution effects, open up evens for starting rural industries and self-employment or gainful employment for rural youth. It is more relevant way to avoid migration of youth from villages to the urban area in search of employment.
Despite their potential economic uses, the valuable natural resources have remained, more or less commercially unexploited. If the technologies developed are properly adopted particularly in the rural area of our country, it will provide supplementary occupation and means of uplift of the financial conditions and living standards of our villages.
Therefore besides use as fuel, it can utilized for the production of boards, animal feeds,etc.Bulk density of agricultural wastes are very low hence for the industries based on it there is a problems of handling and transportation as this increases the cost of final products. Hence the size reduction or volume reduction is very much important for effective utilization of all these sort of wastes.
Looking all these aspects and to utilize agricultural waste in industries as well as in manure effectively, the research work on “Design and development of agricultural wastes shredder” was carried out with the following objectives.
Table of Contents
I INTRODUCTION
II REVIEW OF LITERATURE
2.1 Harvesting and transporting of wastes
2.2 Handling and storage of wastes
2.3 Cutting energy and moisture content
2.4 Industrial use of agricultural wastes
2.4.1 Use in the production of boards
2.4.2 Use in pulp and paper making
2.4.3 Filler
2.4.4 Source of lignin
2.4.5 Production of micro-crystalline cellulose
2.4.6 Production of sugars
2.4.7 Production of furfural
2.4.8 Animal feeds
2.5 Use in the production of organic manure
III MATERIALS AND METHODS
3.1 Physical properties of agricultural wastes
3.2 Design and constructional details
3.2.1 Design of various units
3.2.1.1 Cutting unit
3.2.1.2 Shield and concave
3.2.1.3 Feeding unit
3.2.1.4 Machine frame
3.2.1.5 Outlet
3.2.2 Selection of standard assembly
3.2.2.2 Source of power
3.2.2.3 Power transmission system
3.2.2.4 Compression spring
3.3 Working principle
3.4 Economics of machine
3.4.1 Cost of construction
3.4.2 Cost of operation
3.5 Performance evaluation
IV RESULTS AND DISCUSSION
4.1 Physical properties of agricultural wastes
4.1.1 Moisture content
4.1.2 Bulk density
4.1.3 Organic matter and ash content
4.1.4 Stalk length
4.1.5 Root / Stem diameter
4.1.6 Top width
4.1.7 Weight of stalk
4.2 Design of main components
4.2.1 Cutting unit
4.2.1.1 Shaft
4.2.1.2 Disc flywheel with hub
4.2.1.3 Cutting blades
4.2.1.4 Concave
4.2.2 Feeding unit
4.2.2.1 Feeding trough
4.2.2.2 Feed rollers
4.2.3 Machine frame
4.3 Selection of Standard Assembly
4.3.1 Source of power
4.3.2 Power transmission systems
4.3.2.1 V-belts and pulleys
4.3.2.2 Chain and sprockets
4.3.2.3 Speed reduction unit
4.3.3 Compression springs
4.4 Cost of Construction
4.5 Performance Evaluation
4.5.1 Cutter head speed and length of cut pieces
4.5.2 Capacity and fuel consumption
4.5.3 Chopped density and volume reduction
4.5.4 Operation time and cost
V SUMMARY AND CONCLUSIONS
VI SCOPE FOR FUTURE WORK
Research Objectives and Key Topics
The primary research objective is to address the issue of unutilized agricultural crop residues by designing and developing an efficient shredding machine. The research focuses on converting bulky agricultural waste into smaller, manageable particles to facilitate industrial use and improve soil fertility through rapid decomposition, thereby reducing the environmental impact of waste burning.
- Analysis of physical and mechanical properties of agricultural wastes (e.g., castor, cotton, pigeon pea).
- Design and fabrication of a power-operated disc-flywheel type agricultural waste shredder.
- Performance evaluation of the machine regarding shredding capacity, power requirements, and fuel consumption.
- Economic analysis of the shredding process, including construction and operational costs.
Excerpt from the Book
3.3 Working Principle
The agricultural wastes like stalks of castor, cotton and pigeon pea are fed into the cutting unit through feeding trough. The feeding was done from root side of the stalk. The disc flywheel type cutter head having three hardened steel blades are mounted in radial positions on one side of a disc flywheel. The cutting blades cut the fed materials against the shear plate. The cutting and finer cutting blades on a disc flywheel pulverize the fed material against a slot type metal screen (concave). The shredded material passes through the concave and conveyed to the discharge outlet.
A 6.0 hp diesel engine was used to supply the power to cutter head and feed roller takes power from cutter head to speed reduction unit.
Summary of Chapters
I INTRODUCTION: Discusses the significant volume of agricultural waste in India, the problems associated with its bulkiness and traditional disposal methods like burning, and the necessity of developing efficient shredding technologies.
II REVIEW OF LITERATURE: Examines existing research on the physical and mechanical properties of agricultural residues, their potential industrial applications, and previous efforts in shredding and densification technologies.
III MATERIALS AND METHODS: Details the design parameters, constructional specifications, and working principles of the developed shredder, including the methodology for evaluating its performance and economic feasibility.
IV RESULTS AND DISCUSSION: Presents and analyzes the collected data regarding the physical properties of selected stalks, the design efficacy of the machine components, and testing results concerning capacity, fuel consumption, and shredded output.
V SUMMARY AND CONCLUSIONS: Recapitulates the core challenges, the machine design process, and the research conclusions, emphasizing the potential for industrial utilization of shredded residues and effective waste management.
VI SCOPE FOR FUTURE WORK: Suggests potential future modifications, such as testing the machine with electric motors, tractor PTO power, or optimizing the feeding unit for diverse types of agricultural residues.
Keywords
Agricultural waste, shredder, stalk shredding, castor stalks, cotton stalks, pigeon pea stalks, disc flywheel, mechanical properties, volume reduction, organic manure, soil fertility, industrial utilization, machine design, performance evaluation, cost estimation
Frequently Asked Questions
What is the primary purpose of this research?
The research focuses on designing and developing a shredding machine to convert bulky agricultural waste, such as castor, cotton, and pigeon pea stalks, into smaller particles to make them suitable for industrial use and faster decomposition for soil enrichment.
What are the main agricultural residues studied?
The study primarily focuses on the stalks of castor, cotton, and pigeon pea (tur), which are significant sources of agricultural waste in the Gujarat region.
What is the core objective of the shredder design?
The main objective is to design a shredder with a capacity of 200 kg/h that can effectively reduce the volume of bulky residues to facilitate easier handling, storage, and transport.
Which power source does the machine utilize?
The machine is powered by a 6.0 hp, 1800 rpm air-cooled, single-cylinder diesel engine.
How is the machine's performance evaluated?
Performance is evaluated through testing the machine at various cutter head speeds (200, 350, 500, and 600 rpm) to determine its capacity, fuel consumption, and the size distribution of the shredded material.
What are the key keywords for this study?
Key terms include agricultural waste, shredder, stalk shredding, disc flywheel, mechanical properties, volume reduction, organic manure, and machine design.
Why is the "critical speed" of the cutter head important?
The critical speed, determined to be 500 rpm, is the operational speed at which the machine achieves its best performance in terms of higher percentages of finer cut pieces and optimal shredding efficiency.
How much does the storage volume decrease after shredding?
The study found that shredding can reduce the storage volume of agricultural stalks by approximately 5 times compared to the volume required for whole stalks.
- Quote paper
- Vinaychandra Vagadia (Author), 2008, Design and Development of Agricultural Wastes Shredder, Munich, GRIN Verlag, https://www.grin.com/document/272882
