----- Original Message -----
Sent: Saturday, January 29, 2011 4:23 PM
Subject: Hay Pelletizer / Biomass Machine follow-up
Hey!
I was thinking a little more about that hay mower/
shredder/ pelletizer rig or a stationary operation this afternoon. Was
thinking something like this initially in regard to a cut in half propane tank
unit:
....However, you can't just direct feed the bale as
depicted above. A shredding step is required first, unless the rollers are
also shredders. So, you either have better machined rollers than a
well casing, or modify the well casings, or run a shedder phase first. One
option on a cheap shredder might be to take a wrecking yard manual transmission
and cut away both sides of the tranny casing...leaving the gears
exposed. Hopper feed into it. PTO drive. The gears of the
transmission are case-hardened steel and better engineered for stress than
any garden shredder. Hay put into a transmission will emerge shredded in
really small fragments. Junkyard cores go for about $20.
...Alternatively....do the shredding process on the
roller face.
SHREDDING
EXAMPLES
* For high volumes and low cost, I think the
Papercrete tank with a lawnmower blade and junkyard axle make the most sense,
but not towed. PTO or electric motor driven. Water added, flour,
corn oil, binders, etc. Pulp then run into the pelletizer at a suitable
moisture content prior to compression. Would take a little trial and
error.
PELLETIZER
EXAMPLES
* In light of more study, I think my earlier
idea of a butchered propane tank is not good. Though capable of higher
volumes, it'll take more shafts, longer shafts, more bearings, and more
mechanical engineering. I now favor just an expanded design that
would be just a larger version of the PTO pelletizer highlighted in red
above. The MakeYourOwnPellets people make some suitable dies and
rollers, but they're too small for any high volume throughput. Best to
machine your own at larger scale. Same general design.
These were some ideas and machining costs on the
extruder plates for the propane tank pelletizer idea:
As drilled 1/2" plate. Image depicts 4 bolt
holes on the corners. There should be 2 more in the center (for resistance
to bending under all that pressure) that I forgot to draw.
1/2" single plate x 2" x 6", Al 6061 T6, +/- .005"
tolerance
$177.56/ each w/ shipping. 27 days out to machine it without
rush order costs.
Order of 12 = $60.80 each.
(Originally, I had considered aluminum due to rust
considerations, though they would wear out sooner.)
108 holes per plate - 6 bolt holes = 102 holes per
plate.
As O1 Oil hardened steel. $335.25/
ea
12) 142.95 ea
As 303 stainless steel:
1) $273.44 ea.
12)
$140.95 ea
** Cheaper to just buy the flat
barstock and drillpress it yourself, or hire a kid. Figure about
1/2 hr marking and 1/2 hour drilling per plate. About 1hr/ plate
total. Minimum of around 12 plates needed on a 6' long propane tank
unit.
Depending on the material selection and loading
pressures...1/4" plate could be used at about 1/2 the cost:
Al 6061 T6, 1/4" single plate, $146.30 ea
12)
$31.02/ea.
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