Presented by

Eng. D R Pullaperuma –ChairmanProject Engineer

Eng. N K Edirisinghe With Guidance Provided by

Eng. D D A Namal, Director General Eng. Parakrama Jayasinghe, Board Director

NERD Centre Established as a pioneer engineering R&D

institution Our strengths as at nowCivil - Cost Effective Housing Technology -A house with desired quality at an

affordable price Design, Fabrication & Consultancy to Industry

- Intricate dies and moulds Mechatronics Agriculture & Post Harvest

- Support for plantation and agricultureRenewable Energy

Cost Effective Housing TechnologyCost effectiveness in areas

◦ Plinth beam as against rubble foundation ◦ Pre-stressed concrete columns ◦ Slip form wall ◦ Cement soil block wall ◦ Pre-stressed concrete door and window

frames◦ 2” thick composite concrete floor slab ◦ Pre-stressed concrete trusses & purling

for roof

Cost Effective………………… Contd.◦ Library projects for schools in Monaragala,

Anuradhapura Districts with the initiation of Presidential Secretariat

◦ The Civil Defense personnel engaged in constructions

◦ Architect Mr. G S J Disanayake, BoD introducing architectural input to cost effective buildings

◦ Pollonaruwa Nurses Quarters’ presently being construction with such architectural inputs

◦ Designed 500 sq.ft. 2 story green building to tourist industry – Await stakeholder to construct same at a hotel site.

Design, Fabrication and Consultancy to Industry

We can offer to the industry Intricate dies and moulds Computer aided 3D modeling CAD/CAM applications

CNC machining Plastic injection mould design and manufacture using CAD/CAM

Reverse engineering solutions to industry

Design, Fabrication…………. Contd.Design and manufacture of injection moulds, rubber pressure moulds and press tools for plastic, rubber and sheet metal industry

Use of saw dust and paddy husk in plastic processing

Development of CNC controlled PCB Drilling and Engraving Machine

For the future Development of Versatile Robot Arm for moulding industry

Mechatronics Need assessment

Provide industry automation solutions using ◦PLC◦Pneumatic ◦Electro-pneumatic ◦Electro hydraulic◦Servo and stepper motor control

Offer training using a training simulator

Mechatronics …………… Contd.Dr. Rohan Munasinghe, BoD specialized

Mechatronics Engineering provides guidance

to the NERDC

Mechatronics Design Centre proposed to be

built at Homagama Science Park as an

extension of the NERD Centre

Few projects on Mechatronics to be developed

in collaboration with Moratuwa University.

Agriculture & Post Harvest Technology

Support for plantation and agriculture

Appropriate farm mechanization developed

-Bund cutting machine

-Mechanized Fertilizer Application for

coconut trees

Agriculture & Post……… Post Harvest support

- Motorized m/c for extracting palmyrah juice and pulp

-Virgin coconut oil extractor (HH & industry )

-Industry string hopper making m/c-Vegetable Slicer (Manioc)-Items developed for pepper harvesting

- Development of Flap Gate for irrigational purposes

Renewable Energy Biogas Biomass

◦Household ◦Industry

Wind Energy◦For Water pump ◦For electricity generation

Micro Hydro testing facility Cost effective crematorium/incinerators using LP gas

What we anticipate at this Market Place

Need assessment

Identify the needs of the Industry for

R&D

New areas of industry for collaboration

Partners for existing areas of research

New Licensees for products developed

1.Bio mass rice 1.Bio mass rice cookercooker

Biomass product for the Household – 2 important Items

Can cook 01 kg rice using the 2 shells of 01 coconut. Cooking time - 40 min. No over cooking or burning at the bottom No blackening of the rice pan Can keep rice warm for 07 hours Can boil 2.5 -3 liters of water

Solves environmental problem due to throwing of coconut shells to the surrounding.

Can make 100 nos. of string hoppers.

Main featuresMain features

Existing Licensees 6 No

2. Natural Draft Wood gas 2. Natural Draft Wood gas stovestove2. Natural Draft Wood gas 2. Natural Draft Wood gas stovestove

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Operation type - batch Operating time - 50 - 60

min. Capacity - 600g Can cook - 01KG of rice

300g sprats

250g of darl

Mallum

Main featuresMain features

04/21/23

Industrial stoveIndustrial stove Industrial stoveIndustrial stove

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Biomass Product for the Industry

FeatureFeaturess • FuelFuel : Fire : Fire

woodwood

• Capacity Capacity : 20 litre : 20 litre

• Fire wood consumption rate Fire wood consumption rate : 04 : 04 kg/hrkg/hr

• No ash added to foodNo ash added to food

• PortablePortable

• NO heat and smoke exposure to the NO heat and smoke exposure to the operatoroperator

• Heat controllableHeat controllable

18

ApplicationsApplications Large scale cookingLarge scale cooking

04/21/23 19Existing Licensees 3 Nos

• Hotels

•Canteens

•Refugee Camps

• Army Camps, etc.

Small & Medium Scale Industries

• Milk industry • Kithul industry • Confectionary industry • Ayurvedic industry

03 Technologies for domestic and cottage level industries

Need more New LicenseesPresent License Charge - Rs.7500/-

(Wood Gas Stove and Rice Cooker) , Rs.10,000 (Industrial Stove)

Annual Renewal Fee - Rs.1500 (Wood Gas Stove and Rice Cooker) , Rs.1000 (Industrial Stove)

Chip wood feeding combustion chamber

As against log wood or Jungle wood burning

Can eventually feed Grilicidia piecesSupport sustainabilityEven combustionField trials very encouraging

Why Chip Wood

End of Oil is already here. Coal is not far behind

How is Sri Lanka Affected in a Scenario of Depleting Fuels?

Over dependence on fossil fuelsDrain on foreign exchange We have no proven fossil fuel reservesExploration in progress, promises natural gas

- commercially viability yet to be assess Exploration and commercially viability of oil ?Fuel Imports $ 3.0 Billion per Year and risingFuel Imports $ 3.0 Billion per Year and rising

Should we not think of Bio Mass

Energy Options for Industry

In a scenario of

Depleting fossil fuels

Energy Consumption by Sector in 2007

(Total 8,233.0 TOE)

LOCAL ENERGY SCENARIO

• Overall Scenario by Sector / Source

26%

26%

48%Industry

Transport

HH, Comm, & Other

71%

17%12% Biomass

Petroleum

Electricity

25

Energy Consumption in Household, Commercial & others by Source in 2007

(Total 3,987.8 TOE)

Energy Consumption in Industry by Source in 2007

80%

9% 11%Biomass

Petroleum

Electricity

(Total 2,111.0 TOE)

We have Emphasized on Biomass

To maximize the use of indigenous resourcesReduce over dependence on fossil fuelsReduce drain on foreign exchange Adoption of eco friendly and sustainable practicesEncourage growing grilicidia & use for combustionCarbon Neutral

Why did we select Tea Sector•524000 MT of annual Consumption of fuel wood

•70% of the total fuel wood consumption in Agro-Industrial sector is used by Tea Industry

•Wood Logs are the main form of fuel wood•Logs from Rubber plantations•Logs from jungle fuel wood

Hence Improving Efficiency of Combustion is a dire need

Use of Biomass Energy in Tea Use of Biomass Energy in Tea IndustryIndustry

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Estimated total fuel wood consumed by Tea industry– 326,000 MT

Rubber – 294,000 MT + Other 32,000 MT

Main Use •Generating hot air for drying tea

Other Uses•Withering

Switching from wood logs to Switching from wood logs to wood chips wood chips

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Combustion airCombustion air

Wood log

Wood chips

100 units

100 units

50 units - EXCESS

25 units - EXCESS

How wood chips can improve the efficiency?

• Wood chips dries fasterWood chips dries faster• With wood chips mechanized feeding possibleWith wood chips mechanized feeding possible

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Conventional system of manual Conventional system of manual feeding of feeding of Wood logsWood logs

Improved mechanizedImproved mechanizedsystem for feeding of system for feeding of

wood chips at Deenside wood chips at Deenside Tea Factory, Gampola Tea Factory, Gampola

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ANIMATED IMPROVED SYSTEM

HEAT EXCHANGER

TEMPERATURE SENSOR

TEA DRYER

FURNACE

GRATE

MOTORCONTROLLER

Dryer Inlet Air Temperature - Compared

0102030405060708090

100110120

10.00 10.50 11.4 12.30 13.20 14.10 15.00 15.50 16.40 17.30Time - hr

Te

mp

era

ture

(0 C

)

Rubber wood chips

Glricidia pieces

Wood logs

04/21/23 34

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CONTINOUS CHARGING OF FUEL WOOD CHIPS USING SCREW CONTINOUS CHARGING OF FUEL WOOD CHIPS USING SCREW TYPE FEEDING SYSTEM TYPE FEEDING SYSTEM

AdvantagesAdvantages11). Could be retrofitted to existing system ). Could be retrofitted to existing system without any modifications.without any modifications.

2). At any time the system could be 2). At any time the system could be reverted back to conventional systemreverted back to conventional system

3). Charging of wood chips is required at 3). Charging of wood chips is required at 20 – 30 minutes intervals.20 – 30 minutes intervals.

4). Controlled feeding of fuel wood can be 4). Controlled feeding of fuel wood can be achieved.achieved.

5). Specific fuel wood consumption can be 5). Specific fuel wood consumption can be maintained 0.7 0 1 kg of fuel wood chips maintained 0.7 0 1 kg of fuel wood chips per kg of dried tea.per kg of dried tea.

Cost of the equipment LKR. 800,000.00 Simple payback period < 1 yr

FLEXIBLE TYPE SCREW FEEDING SYSTEM WITH ATWIN-SCREW DISTRIBUTION SYSTEM FOR FUEL WOOD CHIPS

The new wood chips feeding system developed.

Specific consumption of fuel wood in tea Specific consumption of fuel wood in tea manufacturingmanufacturing

Specific consumption of fuel wood (Fuel wood/Made Tea) is in Specific consumption of fuel wood (Fuel wood/Made Tea) is in the range ofthe range of

1 – 2.3 kg fuel wood / kg Made tea1 – 2.3 kg fuel wood / kg Made tea

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Type of fuel wood Moisture content of fuel wood % (WB)

Quantity of dried tea (kg)

Quantity of fuel wood (kg)

Fuel wood/Dried Tea

Rubber fuel wood chips 20 - 35 3237 2298 0.71

Gliricedia & jungle fuel wood chips 25 - 45 1829 1628 0.89

Performance of pilot plant of wood chips feeding Performance of pilot plant of wood chips feeding system in tea drying system in tea drying

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Improved biomass combustion Improved biomass combustion system for Tea Industrysystem for Tea Industry

The second largest black tea producer in the worldTotal employment for over one million people.As a GHG, carbon dioxide (CO2) is the single largest

contributor to climate change. Fuel consumption by the tea sectors in India, Sri Lanka and

Vietnam contribute to CO2 emissions annually by 1.352 millions, 0.708 and 0.085 million tons respectively.

Thus a need has arisen to promote and adopt Energy Efficient and Environmentally Sound Technologies (E3ST) in the tea sector.

Hence the need for adaptation of this new technology by factory owners using either diesel or logwood for combustion 04/21/23 39

The Next Step 550 factories (approx.) uses logwood for combustion 50 factories (approx.) uses diesel for combustion 5 Nos. of licensees given the technology developed

previously. Drier capacity 130 Kg/hr.NERDC has now developed the technology to suit

even higher capacity factories (270 Kg/hr. and above).

Need new/existing licensees to undertake conversion

From a national point of view this conversion is very necessary (very soon there will not be adequate quantities of logwood for tea drying)

Existing Licensees In 2006 given to 4 Nos. of licensees (Rs.25,000 initial payment and Rs.5000/- annual renewal fee )

M/s Puritas, Colombo M/s Metropolitan, Colombo M/s Helix, Colombo M/s Mavusta, Panadura

In 2010 given to M/S Glide, Boralasgamuwa (Rs.25,000 initial payment and Rs.5000/- annual renewal fee )

No records of conversions carried out

Constraints Preventing Wide Spread Adoption Biomass Energy Technologies

Lack of awareness of the advantages and availability of technologies

Fear of shortage of biomass suppliesLack of capital for conversionCost of energy not being a major

component of the cost of production and thus not being considered a priority.

Lack of awareness on the requirement of sustainability.

04/21/23 42

World Energy Outlook for Bio MassWorld Energy Outlook for Bio Mass

Renewable Energy in focusRenewable Energy in focus

Green production attracting Green production attracting premium pricespremium prices

Buyers demanding low carbon Buyers demanding low carbon footprints for productsfootprints for products

4343

As it is the Sri Lanka SituationAs it is the Sri Lanka Situation

If Gliricidia is grown can even If Gliricidia is grown can even reduce the Importation of Urea reduce the Importation of Urea Fertilizer Fertilizer

Saving on Fertilizer SubsidySaving on Fertilizer Subsidy

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