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ABSTRACT

MIT's D-lab developed a method to turn agricultural wastes into affordable smokeless fuels, such as sugarcane charcoal and corn cob charcoal. This agricultural waste charcoal has the potential to combat deforestation and reduce the dangerous effects of indoor cooking fires. One limiting factor in the adoption of this technology is the need for a charcoal crusher.

Burning carbonized cobs produces less smoke than regular biomass fuels, but the carbonized cobs produce a hazardous level of carbon monoxide. D-lab developed a device to turn charcoal powder into a dense compact briquette that burns safely, but it is difficult to crush the carbonized cobs into a charcoal powder without inhaling dangerous amounts of charcoal dust. Our team's charcoal crushing device addresses the gap in this alternative fuel process.

For further information contact the team at: mailto:crushers@mit.edu

Team Information

  • Joshua Cholobesa, Mumbwa District Councilor, Zambia
  • Nathan Cooke, Product Design, Art Center College of Design in Pasadena, USA
  • Bernard Kiwia, Mechanic and Electrician, Instructor of Appropriate Technologies at Global Alliance Vijana Centre, Tanzania
  • Sumit Pahwa, Manufacturing Engineering, Sant Longowa Institute of Engineering and Technology, India
  • Jessica Vechakul, Mechanical Engineering, MIT, USA

Introduction

Problem Definition

More than two billion people use wood, charcoal, dung or agricultural residues as the primary fuel for their cooking and heating needs, leading to significant health, economic and environmental consequences:

  • Almost 2 million deaths each year are caused by breathing smoke from indoor cooking fires [1]
  • Respiratory infections are the leading cause of death of young children worldwide
  • An estimated 50 billion hours are spent collecting firewood each year
  • In some areas where wood and charcoal are scarce, more than a quarter of a family’s income is spent on fuel

Understanding the Market

Capital Investment

  • Oil Drum $10
  • Charcoal Crusher $25
  • 3 Briquetters $6

Total $41

To make a numbered list use the pound sign:

  1. Like this
  2. and like this

Design Requirements

Low cost: $20-$50

  • Currently, carbonized cobs are crushed by stepping on them or hitting them with heavy objects like cinder blocks. Inhalation of charcoal dust is reduced by placing carbonized cobs in a rice sack lined with a plastic garbage bag that is lined with another rice sack. The plastic garbage bag develops holes during the crushing process and must be replaced after each batch. If an entrepreneur makes 5 batches of charcoal per day, he will use 25 plastic bags per week or about 1250 bags per year (if he works for 50 weeks per year). If a box of 25 bags cost $2, a year's worth of bags will cost $100. In order to encourage users to buy our device, we are designing a device that is half the cost of the current alternative.


Fast: 6 pounds in 10 min.

  • Each batch of carbonized cobs is about 6 pounds, and can be crushed by stepping on it in 10 minutes. Our device

is designed to be just as fast.


Safe: minimizes inhalation of charcoal dust

  • The device limits the user's exposure to the charcoal dust that is harmful when inhaled. Charcoal dust consists of super fine particles of charcoal that are thrown into the air when the carbonized cobs are being crushed or when the charcoal powder is being transported or agitated. To minimize transfer of the charcoal powder from one receptacle to another, the device deposits charcoal powder directly into the container where it is mixed with a wet

binder. After the user deposits carbonized cobs into the device's hopper, the lid prevents the charcoal dust from escaping.

Locally fabricated with available materials

  • Both models of the device consists of wooden boards and common steel pipes and rods. Depending on the materials available, the grating cylinder can be made from expanded steel tack welded to a steel pipe, or cement poured into a mold made from a PCV pipe. Both models can be made with hand tools and welding.

Transparent design

  • The device is a transparent design that is intuitive to use and repair.

Design

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Costs

Capital Investment

Item Cost
Oil Drum $10
Charcoal Crusher $25
3 Briquetters $6
Total $41

1 oil drum yields 5kg of carbonized agricultural waste. 50kg of charcoal briquettes sells for $30 to the customer.


Variable Cost

Item Cost
Cassava (binder) $0.51
Transportation $1.46
Packaging $1.50
Labor $15
Total $18.82

Cost to the Customer $30
Variable Costs -$18.82
Total Profit $11.18

Scenario 1
  • 1 oil drum of carbonized cobs a day
  • $11.18 profit per 50kg per 10 days
  • $1.12 profit per day
  • 37 days to pay back $41 capital investment
Scenario 2
  • 2 oil drums of carbonized cobs a day
  • $11.18 profit per 50kg per 5 days
  • $2.24 profit per day
  • 22 days to pay back $41 capital investment

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