Research and design of 5.4-inch diameter mold rotary press for coal log and biomass compaction

Abstract

The research and development (R&D) of coal log compaction machines is very important for commercializing tl1e new technology of coal log pipeline (CLP). The CLP technology will be successful commercially only if the machine can produce high-quality, low-cost coal logs at a high production rate. In this thesis, a commercial scale rotary press for compacting coal logs and biomass logs is designed. This machine is not a small, conventional tablet rotary press used by the pharmaceutical industry. It is one of the largest rotary presses in the world. This machine provides a maximum of 250-ton compaction force, and can produce coal logs of 5.4 inches in diameter and 10 inches in length. The designed production rate is 3,600 logs per hour or one log per second. Because of the large friction force and the long stroke, the design of such a machine is very challenging. In order to satisfy all design requirements and overcome technical problems, the critical components such as the cam, the punches, the turret, the feeding system, and the power train are carefully analyzed and designed. The design also incorporates special features learned from coal log compaction studies such as the backpressure during ejection of logs from mold. The cost estimation for this design is also conducted. As a result of the preliminary design, a set of assemblies, subassemblies, and main part drawings is provided with this thesis.