FIELD OF INVENTION
The subject invention relates to a device for manufacturing an agro-waste and sponge iron industrial waste cake having a plurality of air passages.
The embodiment of the invention resides in the circumferentially placed uniformly distributed air passages for uniform burning and maximum heat generation.
PRIOR ART
WO 2012142489 A1 teaches about an invention which provides processes and systems for converting biomass into highcarbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt%, 80 wt%, 90 wt%, 95 wt%, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects.
Indian Patent No.221468 teaches about an invention which relates to a device for manufacturing an agrowaste cake having a plurality of air passages comprising a compactor assembly, a cake air passage die having a top plate, a plurality of pins having tapering conical ends and spring loaded compacting plate with plurality of holes and support rods , a cake die for receiving the agrowaste material and an ejector assembly having a cake plate placed below base plate of said cake die , a lever and a column guide fixed firmly to the said device, to eject the agrowaste cake so manufactured from the said cake die.

OBJECT OF THE INVENTION
The object of the invention is to produce cakes with uniform density and uniformly circumferentially placed holes to get uniform burning with less fuel consumption.

SUMMARY OF THE INVENTION
5 million tones of sponge iron waste per annum is generated in India from about 200 coal based sponge iron (SI) industries spread over in four states – Jharkhand, Orissa, West Bengal and Chattisgarh. These wastes are being dumped into the communities in the vicinity of more than 2000 villages causing serious environmental challenges to complete eco-system like water bodies, agriculture, animal and human. Converting such waste into cakes can fulfill cooking energy need of several million families per annum at the affordable cooking cost.
Agricultural wastes are difficult to be handled because of their bulky and scattered nature, low thermal efficiency and copious liberation of smoke.
The loose agro-residues made after carbonization and sponge iron waste after processing into manageable pieces or cakes in cylindrical shape having plurality of holes are called “Energy Cakes”. These Energy Cakes give high thermal value smokeless energy source like liquid petroleum gas. The preparation of these Energy Cakes manually with the help of a mould or manually operated machine is very inefficient and time consuming process. The mould for the preparation of such cakes as known conventionally is a three piece body consisting of bottom plate with protruding rods, a middle cylinder to fit the bottom plate and a perforated plate to slide down along the rods into the cylinder. At the time of manufacturing such cakes, all the three parts of the mould are first assembled and the raw material is poured in it and once the cake is prepared, all the three parts of the mould are separated one by one to get the cake so prepared. The manually operated machine as disclosed in the Indian Patent No.221468 has been designed to overcome to some extent the disadvantages like the lack of uniformity, more time consuming, lesser production rate. The device of the subject invention has been developed to have enhanced production rate many times the manually operated machines without compromising the uniform density. This subject invention produces “Energy Cakes” of high quality to give near complete combustion and thereby improving the energy efficiency and competitive cost of these cakes.
The subject agro-waste and sponge iron waste cake (called Energy Cake) manufacturing device has been found to give excellent quality cakes out of agrowaste and sponge ion waste besides producing cakes efficiently with respect to increase in the number of such cakes so prepared and consuming less time for the preparation of such cakes.

DETAILED DESCRIPTION OF THE INVENTION

“Energy Cake” is a fuel manufactured from agro wastes and sponge iron wastes. It is clean and cheap. The “energy Cake” has been scientifically designed which touches temperatures as high as 700oC and burns up to 2 hours. The cake so prepared have been found to be easy in transportation and storage. These cakes can be utilized for cooking and other small industrial applications.
For the production of such energy cakes in the device of subject invention, the biomass is first heated at a temperature of between 248-260o C in the controlled conditions to produce char. In the char so produced is added clay in the ratio of 15-35% by weight and or processed sponge iron waste in the ratio of 35-55%, to form a mixture. The said mixture of char and or sponge iron waste and clay is then moistened to form a semi-solid paste of uniform consistency. The said semi-solid paste is then transferred into the hopper of subject device to prepare cake. These cakes are then dried. The clay used in the subject mixture acts as binder as well as energy extender.
The energy cake manufacturing device of the present invention is designed to manufacture compacted cakes with moistened clay acting as binding agent. The subject device for manufacturing Energy Cakes comprises a compactor assembly, gear assembly, feeding assembly and ejection system.
Compactor assembly consists of slider, pressing mechanism and mould plate. The slider attached with gear through arm to give vertical movement to the pressing mechanism. The mould plate is attached with the gear through cam to give the high accuracy rotational motion. The pressing mechanism is having a top plate, air passage die means for the formation of air passage holes and a spring loaded compacting plate having plurality of holes and support rods. The diameter of the top plate is 140-150mm and the thickness of the top plate is 12-16mm. The top plate is fitted with 19 pins or 39 pins having tapering ends of length 130-160 mm and diameter of 12-15mm. The said pins are arranged in a circle where the said pins are spaced apart from each other by 24-30mm. The spring loaded compacting plate is a circular plate having a diameter of 130-138mm and thickness of 12-16mm. The spring loaded compacting plate is provided diameter with the conformity to match with the inner diameter of cake mould. The spring loaded compacting plate is provided with holes in conformity to the diameter of pins of the top plate to allow the pins of the top plate to pass through the spring loaded compacting plate. The compacting plate is fitted with four support rods of the diameter 12-14mm and the length of 140-175mm located on the periphery of the said plate. These support rods pass through the top plate and the springs of the plate force back to its position after the top plate is raised from cake die.
The compacting plate acts as the cover on cake mould to arrest the semisolid agrowaste and or sponge iron mixture from spilling over. The compacting plate compresses the semi-solid agrowaste mixture loaded in the cake mould, when the top plate moves down to form air passages in the cake. The compacting plate also acts as a retainer plate to ensure smooth withdrawal of pins from the cake after compacting the same.
The cake mould is a cylinder having the diameter of 132-140mm and length of 80-115mm. There are six cake moulds which are fitted on a cake plate. The cake plate is mounted on a base plate attached in the housing.
The another important part of the said machine is the ejection system, which consists of a ejector and a conveyor belt. The ejector attached to the slider has a rod and a plate at the bottom of this rod. The slider gives up and down movement to the ejector. The outer diameter of plate of the ejector matches with the inner diameter of cake mould to eject the said cake from the said cake mould after each cycle of vertical motion of slider. The ejected cake is moved out for collection and drying with the help of conveyor belt provided at the bottom of the cake mould.
The feeding assembly comprises of a hopper and a blade in it. The semi solid paste of agro-waste material or sponge iron waste material mixed with clay is poured in the hopper. There is a blade in the hopper which pushes the semi solid paste into cake mould when the cake mould is stationary before each cycle of vertical motion of slider. Then the material is taken in the cake mould above the plate on top of housing for compression and air passage holes under the compactor assembly.
Motions to all the parts namely slider for vertical motion, cam for rotational motion, gear assembly for rotational motion, blade in the hopper for rotational motion and the conveyor belt for forward carrying motion are powered by a motor attached to the coupling arrangement.
The subject invention can be best illustrated with reference to the accompanying drawings which is for illustrative purposes and should not in any way construed to restrict the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 depicts the assembly of the device for manufacturing Energy Cake having a plurality of air passages.

DETAILED DESCRIPTION OF THE DRAWING
The subject device as shown in figure 1, for manufacturing an Energy Cake having a plurality of air passages comprises a compactor assembly, gear assembly, feeding assembly and ejection system. Compactor assembly further comprises slider (1), pressing mechanism (2) and mould plate (3). Gear assembly comprises of cam (5), gear arrangement (6) and coupling (16). Feeding assembly comprises of hopper (13) and a blade (14). Ejection system comprises of ejector (12) and a conveyor belt (15).
The slider (1) as shown in figure 1 is having a chrome plated column guide (4) for the vertical motion. The mould plate (3) has a cam (5) and a gear arrangement (6) to provide the rotary motion.
As shown in figures 1, the lower portion of the said column guided slider (1) is fitted with the said pressing mechanism (2). The pressing mechanism (2) is having a top plate (7), air passage die (8) means for the formation of air passage holes and a spring loaded compacting plate (9) having plurality of holes and support rods.
The said air passage die (8) is a plurality of tapered pins with pointed conical end preferably 19 pins or 37 pins are attached to the said top plate (7) for the formation of air passage holes.
The spring loaded compacting plate (9) having plurality of holes preferably 19 holes or 37 holes conforming to the number and diameter of the said tapered pins in air passage die (8) of the said top plate (7) of the said pressing mechanism (2) to allow the said tapered pins to pass through the holes of said spring loaded compacting plate(9).
The springs of the said spring loaded compacting plate (9) is attached to the said slider (1) to bring the spring loaded compacting plate (9) to its position after the said top plate (7) is raised from the said cake mould (10).
The cake mould (10) is a cylindrical shape body. There are six cake moulds attached to the mould plate (3). All the six cake moulds (10) are attached to a cam (5). The cam (5) gives rotational motion with high degree of accuracy to cake mould (10) to fit into the top plate (7) of the pressing mechanism (2) after each cycle of vertical motion of slider (1). Vertical motion of slider (1) with the help of an arm (11) and rotational motion of cam (5) are attached to the same gear arrangement (6) to give synchronization to the system and avoid any accident.
The ejector (12) attached to the slider (1) has a rod and a plate at the bottom of this rod. The outer diameter of plate of the ejector assemble (12) matches with the inner diameter of cake mould (10) to eject the said cake so manufactured from the said cake mould (10) after each cycle of vertical motion of slider (1).
The semi solid paste of agro-waste material or sponge iron waste material mixed with clay is poured in the hopper (13). There is a blade (14) in the hopper (13) which pushes the semi solid paste into cake mould (10) when the cake mould (10) is stationary before each cycle of vertical motion of slider (1). The slider (1) brings the cake air passage die (8) downwards. The top plate (7) of the pressing mechanism (2) along with the cake air passage die (8) moves downwards to pass through the holes of spring loaded compacting plate (9) for the insertion of such tapered pins (8) in the cake mould (10) to form air passages in the said semi solid material mixed with clay present in the said cake mould (10). The spring loaded compacting plate (8) presses the said semi-solid mixture and acts as the cover on cake mould to arrest the semisolid mixture from spilling over. The spring loaded compacting plate (9) compresses the semi-solid mixture loaded in the cake mould (10), when the top plate (7) moves down to form air passages in the said cake. The spring loaded compacting plate (9) also acts as a retainer plate to ensure smooth withdrawal of tapered pins(8) from the cake after compacting the same. After the formation of the air passages the top plate (7) along with tapered pins (8) and spring loaded contacting plate (9) moves back to its original uncompressed state by means of tension springs fixed with the slider (1). After the movement of cake air passage die (8) back to its original uncompressed state, next cycle of downward motion of slider (1), the ejector (12) exert pressure on the said cake having plurality of air passages so prepared to eject out of cake mould (10). The ejected cake falls on the conveyor belt (15) below the ejector (12). Motions to all the parts namely slider (1) for vertical motion, cam (5) for rotational motion, gear assembly (6) for rotational motion, blade (14) for rotational motion and the conveyor belt for forward carrying motion are powered by a three hp motor attached to the coupling arrangement (16). All these parts along with the slider (1) joined with the help of a flange (17) assembled into a housing (18) to complete the device.
The air passages on the Energy Cake are circumferentially placed at equal distance from each other. The air passages are so placed to give uniform burning and thus maximum heat generation.

we claims:-
1. A device for manufacturing Energy Cakes having a circumferentially placed uniformly disposed holes comprising a compactor assembly having a slider (1), pressing mechanism(2), mould plate (3), a gear assembly having a cam(5), gear arrangement (6) and the coupling (16), a feeding assembly for feeding the semi solid paste of agro waste material or sponge iron waste material mixed with clay, a feeding assembly having a hopper a blade for pushing the semi solid paste into the cake mould during stationary position and an ejector system for ejecting the cake under pressure on the cake having plurality of air passages so formed to eject out of the cake mould.

2. A device for manufacturing Energy Cake as claimed in claim 1, wherein the compact assembly comprises a slider (1), pressing mechanism (2) and mould plate (3), wherein the slider is provided with a chrome plated column 9 under (4), for the vertical motion.

3. A device for manufacturing Energy Cake as claimed in claim 1, wherein the said mould has a cam (5), and a gear arrangement (6) to provide the rotating motion.

4. A device for manufacturing Energy Cake as claimed in claim 1, wherein the said column guided slider (1) lower portion is fitted with pressing mechanism (2),having a top plate (7), air passage die(8), for the formation of air passage holes a spring loaded compacting plate (9), having an uniformly circumferentially clustered holes and support rods.

5. A device for manufacturing Energy Cake as claimed in claim 1, wherein the said air passage die (8), is having a plurality of tapered pins with conical end for the formation of air passage holes.

6. A device for manufacturing Energy Cake as claimed in claim 1, wherein the spring loaded compacting plate (9), having a plurality of holes conforming to the diameter of the said tapered pins in air passage die (8), of the said top plate(7), of the said pressing mechanism (2), for allowing the said tapered pins to pass through the holes of said spring loaded compacting plate (9).

7. A device for manufacturing Energy Cake as claimed in claim 1, wherein the cake mould is cylindrical in configuration attached to the mould plate(3).

8. A process for manufacturing an energy cake having a plurality of air passage from agro waste and sponge iron waste mixed with clay wherein the said paste is poured into the hopper(13), pushing the semi solid paste into the cake mould (10) during its stationary position by means of a blade provided in the hopper bringing the cake air passage die (8) downwards , moving downwards the top plate(7) of the pressing mechanism (2), along with the cake air passage die (8) to pass through the holes of the spring loaded compacting plate (9) for the insertion of the tapered pins (8), in the cake mould to form uniform air passage, pressing the semi solid mixture by spring loaded by means of compacting plate (8) acting as the cover to cake mould to arrest the said semi solid mixture from spilling over, compresses the semi solid mixture loaded in the cake mould , moving the top plate (7) down to form air passages in the said cake moving the spring loaded top plate (7), along with the tapered pins (8) as spring loaded contact plate (9), along with the tapered pins (8) to the original uncompressed state by means of tension spring pins fixed with the slider , the ejector (12) exert pressure on to said cake having plurality of air passages to eject out of the cake mould , the eject cake falls on the conveyer belt for taking it out.