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Okay, now to my rollers. These are 3"
diameter rollers x 1/2" thick. Making them 1" thick adds way more
expense. They can be made from just a 1/2" x 3" x 3" plate turned on a
lathe and drilled....or from 3" bar rounds cut, ground, and then drilled.
Inner hole drilled to a diameter matching the OD of the selected bearings. Press
fit. Most rollers have square (broached) machining done, but that's more
costly and difficult as do-it-yourself. Here, the radial holes are
set up to allow a really sharp shreeding edge that will just axe away on the hay
or wood chips, but the opening of the mouth is left wide enough to prevent
clogging. The circular nature of things will add some vortex flow of
material to enhance shredding efficiency. Though only 1/2" rollers, you
stack them on the shaft (like dualie wheels on trucks) into a single rolling
array. That allows also for variance in roller RPM with length and
varying resistance encountered
when shredding and compressing. The outward
round face does the compression into the extrusion holes and must be at least a
bit larger than the diameter of the holes.
Rollers (1" thick), T303
Stainless
$235.44 ea
10) $99.34 each
[5 needed]
(1/2" thick), 303 Stainless
Steel
1) $144.73
10) $46.84 ea
[10 needed]
Do-It-Yourself Roller Material Options for
Machining:
3 inch Dia. 304
Stainless Steel Round Bar x 1 foot. $150.18
Tool
Steel D-2 Flat Ground. 1/2 x 3 x 18"....$307.75
1/2" x 3" x 18" tool
steel A2 flat ground, air hardened. $214.43
Tool Steel O-1 Flat
Ground, 1/2 x 3 x 18"....$160.36
3 inch Dia. 1018 Cold Finish Steel
Round x 1' $48.06
1/2 X 3 Cold Finished C1018 Flat Bar,
2'....$33.66
For shafts:
1/2 inch Alloy 4140 Steel Round - Cold
Drawn Annealed, 4' bar...$12
For Bearings:
...Price unknown. Need and RFQ.
The Make Your Own Pellets dies appear to have about
120 holes compared to my design's 416. They
claim about 384 lbs/ hr @ 540 tractor PTO RPM. My design will
probably produce in the range of 1,328 lbs/ hr at the same PTO rpm and should
require about 3.5 times the PTO horsepower, too. About 88 HP
needed. Either take up the RPM and burn more fuel....or probably
better to just get a little, junkyard Toytota 4 banger motor...used, running,
EFI. Something like a 3SFE. Add some HHO for additional fuel
economy.
In comparison, the propane tank unit and a single
row extruder would have 1,224 holes. If running a good set of
rollers like mine (not 5" well casings), it could shred and compress maybe 3,917
lbs/ hr....per roller....and one could gear in about 3 per propane tank.....so,
about 11,751 lbs/ hr pellet production....or maybe about 5.8 tons per hour
capable on a 3 roller rig. That's a capacity to convert maybe 106
three-wire bales/ hr....or about 1 3/4 bales/ minute shredded and transformed to
pellets. You'd need at least a 255 HP engine driving it
now, but that's just a junkyard V-8 or truck's diesel engine on HHO. The
greater the machine can shed and produce, the less time you have to run the
engine per Ton....and less fuel required per Ton. Over a bale/
minute feed-in now starts to justify the cost of overhead and hired labor doing
feeds. And, if you're going to bother building one with self-labor
rather than just off-the-shelf purchases....you might as well go big!
:-) Gives you greater profit margin as a commercial
operation. Most these smaller units would cost more than building a
big one, and you get less production....higher costs per ton produced, etc.
Anyhow, think about that some. Might open up
the pelletized feed and wood pellet fuel market for you. Expands the hay
market options. On a little labor and time spent in a month's work....and
costs about the same as buying another used tractor implement like a
baler...there's a whole new business angle right there for ya. :-)
Stan