Briquettes: Bioenergy and Food Security Rapid Appraisal (Befs Ra) User Manual

BIOENERGY AND FOOD SECURITY
RAPID APPRAISAL (BEFS RA)
User Manual
BRIQUETTES
BEFS Rapid Appraisal
Energy End Use Options Module

__________________________________
Intermediate or Final Products Sub-Module
Section 1: Briquettes
User Manual
Acknowledgements
The BEFS Rapid Appraisal was the result of a team effort to which the following authors, listed in alphabetical
order, contributed1: Giacomo Branca (Tuscia University, Viterbo), Luca Cacchiarelli (Tuscia University, Viterbo),
Carlos A. Cardona (National University of Colombia at Manizales), Erika Felix, Arturo Gianvenuti, Ana Kojakovic,
Irini Maltsoglou, Jutamanee Martchamadol, Luis Rincon, Andrea Rossi, Adriano Seghetti, Florian Steierer,
Heiner Thofern, Andreas Thulstrup, Michela Tolli, Monica Valencia (National University of Colombia at
Manizales) and Stefano Valle (Tuscia University, Viterbo).
Inputs and contributions were also received from Renato Cumani, Amir Kassam, Harinder Makkar, Walter
Kollert, Seth Meyer, Francesco Tubiello and his team, Alessio d’Amato (University of Rome, Tor Vergata) and
Luca Tasciotti.
We would like to thank the Bioenergy and Food Security Working Group in Malawi2 as well as the National
Biofuels Board3 and its Technical Working Group in the Philippines for their involvement in the pilot testing of
the BEFS Rapid Appraisal and the useful feedback provided. We also wish to extend our appreciation to Rex B.
Demafelis and his team from University of the Philippines Los Baños for their valuable support in the pilot
testing exercise.
The BEFS Rapid Appraisal benefited from feedback and comments provided at a peer review meeting held in
February 2014 in FAO Headquarters by Jonathan Agwe (International Fund for Agricultural Development),
Adam Brown (International Energy Agency), Michael Brüntrup (German Institute for Development Policy),
Tomislav Ivancic (European Commission), Gerry Ostheimer (UN Sustainable Energy for All), Klas Sander (The
World Bank), James Thurlow (International Food Policy Research Institute), Arnaldo Vieira de Carvalho (Inter-
American Development Bank), Jeremy Woods (Imperial College, University of London) and Felice Zaccheo
(European Commission). Useful feedback was also provided by Duška Šaša (Energy Institute Hrvoje Požar,
Zagreb).
Furthermore, we would like to express our sincere gratitude to Monique Motty and Ivonne Cerón Salazar for
their assistance in finalizing the tools and documents.
The work was carried out in the context of the Bioenergy and Food Security Rapid Appraisal project
(GCP/GLO/357/GER) funded by the German Federal Ministry of Food and Agriculture (BMEL).
1 Unless otherwise specified, all authors were affiliated to FAO at the time of their contribution.
2 The BEFS working Group in Malawi comprises the following members: Ministry of Energy, Ministry of Lands, Housing, and Urban
Development, Ministry of Finance, Ministry of Agriculture and Food Security, Ministry of Environment and Climate Change and
Department of Forestry, Ministry of Industry and Trade, Ministry of Economic Planning and Development, Ministry of Labour and
Vocational Training, Ministry of Transport and Public Infrastructure, Ministry of Information and Civic Education, Ministry of Local
Government and Rural Development.
3 The National Biofuels Board is chaired by the Secretary of Department of Energy and includes the following members: Department of
Trade and Industry, Department of Science and Technology, Department of Agriculture, Department of Finance, Department of Labour
and Employment, Philippine Coconut Authority, Sugar Regulatory Administration.
BEFS RA User Manual Volumes
I. Introduction to the Approach and the Manuals
II. Country Status Module
III. Natural Resources Module
1. Crops
Section 1: Crop Production Tool
Section 2: Crop Budget Tool
2. Agricultural Residues
Crop Residues and Livestock Residues
3. Woodfuel and Wood Residues
Section 1: Forest Harvesting and Wood Processing Residues
Section 2: Woodfuel Plantation Budget
IV. Energy End Use Options Module
1. Intermediate or Final Products
Section 1: Briquettes
Section 2: Pellets
Section 3: Charcoal
2. Heating and Cooking
Biogas Community
3. Rural Electrification
Section 1: Gasification
Section 2: SVO
Section 3: Combustion
4. Heat and Power
Section 1: CHP (cogeneration)
Section 2: Biogas Industrial
5. Transport
Ethanol and Biodiesel

BEFS Rapid Appraisal – Briquettes Component User Manual
Table of Contents
1 Overview of the Energy End Use Option (End Use) Module ...........................................................................4
2 The Briquette Component ...............................................................................................................................6
3 Terms and Definitions in the Briquettes Component ......................................................................................8
4 Scope and Objective of the Briquettes Component ........................................................................................9
5 Running the Briquette Component ................................................................................................................10
5.1 Step 1: Energy demand..........................................................................................................................12
5.2 Step 2: Defining the feedstock ..............................................................................................................13
5.3 Step 3: Production cost and financial parameters ................................................................................18
5.4 Step 4 (Optional): Calculation of the production cost of briquettes .....................................................20
6 Assumptions and Limitations of the Briquettes Component .........................................................................21
7 The Results of the Briquettes Component .....................................................................................................22
7.1 Overview of the production cost calculations (optional) ......................................................................22
7.2 The summary of results by feedstock....................................................................................................24
7.3 The summary of comparative results ....................................................................................................26
8 Annex .............................................................................................................................................................28
8.1 Methodology and outputs .....................................................................................................................28
8.1.1 Cost calculation of required inputs ...............................................................................................28
8.1.2 Cost calculation of required labour ...............................................................................................29
8.1.3 Cost calculation of required transportation ..................................................................................30
8.1.4 Cost calculation of storage ............................................................................................................30
8.1.5 Fixed cost calculation ....................................................................................................................31
8.1.6 Calculation of other costs ..............................................................................................................32
8.1.7 Total production cost and unit cost of briquette calculation ........................................................32
8.1.8 Briquette demand calculation .......................................................................................................33
8.1.9 Project revenue calculation ...........................................................................................................34
8.1.10 Briquetting technologies ...............................................................................................................35
8.1.11 Database for financial analysis ......................................................................................................36
8.2 Data requirements for running the tool ................................................................................................37
9 References .....................................................................................................................................................39
1
List of Figures
Figure 1: The Structure of the Energy End Use Option Module ..............................................................................4
Figure 2: Biomass Briquette System for Rural and Urban Heating and Cooking ....................................................6
Figure 3: Layout of the Briquettes Results Sheets...................................................................................................7
Figure 4: Rapid Appraisal Tool for Heating and Cooking - Briquettes Component................................................10
Figure 5: Briquettes Component: Flow of Analysis and Inter-linkages with BEFS RA Modules and
Components .............................................................................................................................................11
Figure 6: Energy Demand in Rural and Urban Areas .............................................................................................12
Figure 7: Feedstock Selection ................................................................................................................................13
Figure 8: Feedstock Price Calculation based on the Collection Method and Source ............................................14
Figure 9: Chemical Binder and Feedstock Storage Cost ........................................................................................16
Figure 10: Feedstock Storage Calculator ...............................................................................................................17
Figure 11: General Inputs ......................................................................................................................................18
Figure 12: Production Cost Calculation .................................................................................................................20
Figure 13: Processing Costs of Briquettes .............................................................................................................20
Figure 14: Detail of Production Costs of Briquettes by Production Capacity ........................................................23
Figure 15: Production Cost and Investment Results .............................................................................................24
Figure 16: Operating Results .................................................................................................................................25
Figure 17: Financial Analysis Results .....................................................................................................................25
Figure 18: Layout of Comparative Results .............................................................................................................27
2
List of Tables
Table 1: Specific Feedstock that can be Used in the Briquette System ................................................................15
Table 2: Estimated Cost of Storage .......................................................................................................................17
Table 3: Inputs Cost Equations ..............................................................................................................................28
Table 4: Labour and Miscellaneous Cost Equations ..............................................................................................29
Table 5: Transportation of Feedstock and Briquette Products Cost Equations ....................................................30
Table 6: Storage Cost Equations ............................................................................................................................30
Table 7: Fixed Cost Equations ................................................................................................................................31
Table 8: Other Costs Equations .............................................................................................................................32
Table 9: Total Production Cost Equations .............................................................................................................32
Table 10: Comparison of Briquette with Other Fuels............................................................................................33
Table 11: Briquette Demand Equations ................................................................................................................33
Table 12: Project Revenue Equations ....................................................................................................................34
Table 13: Briquetting Technologies Comparisons .................................................................................................35
Table 14: Investment Cost of the Briquette System..............................................................................................36
Table 15: Data Requirements for Running the Tool ..............................................................................................37
3
1 Overview of the Energy End Use Option (End Use) Module

As explained in the general introduction of the BEFS RA training manual, the Energy End Use Option module
is used to assess the techno-economic and socio-economic viability of different bioenergy production
pathways. The module is divided into five sections, these are: Intermediate or Final Products, Heating and
Cooking, Rural Electrification, Heat and Power and Transport. Each of the sub- modules includes a choice of
components of analysis to assess the production of specific biofuels based on particular processing
technologies, as depicted in Figure 1. This module builds up from the information generated in the Natural
Resources modules in relation to feedstock. For a more detailed description of the module, refer to the
general introduction of the training manual.
Figure 1: The Structure of the Energy End Use Option Module
A general description of each of the sub-modules and their respective components of analysis are
presented below. A more detailed discussion on each of the components of analysis will be provided in the
respective user manual.
The Intermediate or Final Products sub-module is used to assess the viability of producing briquettes,
pellets and charcoal. The Briquettes/Pellets components are used to evaluate the potential to develop the
production of biomass briquettes/pellets to supply energy for heating and cooking in rural and urban
households. The objective of the analysis is to generate information on production cost, biomass
requirements and financial viability and social parameters to help users in their decision to promote
briquette/pellet production in the country. The Charcoal component is used to compare existing charcoal
production technologies with improved and more efficient technologies. The aim of the analysis is to assess
the required upfront capital cost of the improved technologies, the financial viability from the standpoint of
charcoal producers and the social and environmental benefits that improved technologies can trigger when
compared to existing charcoal production technologies. The results generated by the analysis inform on
potential barriers for the uptake of the improved charcoal technologies by producers and help define how
to effectively disseminate their introduction.
4
The Heating and Cooking sub-module is used to assess the viability of producing biogas at the community
level. The Biogas Community component is used to evaluate the potential to develop biogas production
from livestock manures at the household and community levels and compares three different types of
technologies. The component generates information on: 1) the amount of biogas that can be produced
based on manure availability, 2) the size of biodigester needed to harness the energy, 3) the installation
cost of three types of biodigester technologies. The component also provides financial social and economic
parameters to help the user understand the potential opportunities and the requirements needed for
deploying biogas technology in their countries.
The Rural Electrification sub-module is used to assess the viability of supplying electricity from local
biomass resources in remote areas without access to the electric grid. The sub-module is comprised of
three decentralized-based technology pathways for electrification, these are: gasification, use of straight
vegetable oil (SVO) and combustion. The results from this sub-module generate estimates of the cost of
electricity generation and distribution, calculates the financial viability of electrification and informs on the
associated social and economic outcomes for each alternative technology pathway. The Gasification
component analyses the partial burning of biomass to generate a gas mixture that is subsequently
combusted in gas engines to produce electricity. The Straight Vegetable Oil (SVO) component builds on
from the Crops component in the Natural Resources module. It assesses the potential to substitute diesel
with SVO in generators to produce electricity. The Combustion component assesses the burning of biomass
to produce steam which drives a turbine to produce electricity.
The Heat and Power sub-module is used to assess the viability of the production of electricity and heat
from local biomass resources. The sub-module is comprised of two decentralized-based technology
pathways for electrification and heat, these are: CHP (cogeneration) and biogas industrial. The results from
this sub-module generate estimates of the cost of electricity/heat generation and distribution, calculates
the financial viability of electrification/heat and informs on the associated social and economic outcomes
for each alternative technology pathway. The CHP (cogeneration) component examines the potential for
the simultaneous production of electricity and heat from a biomass source, allowing the user to analyse a
factory integrated production or a standalone operation for pure grid electricity generation. The Biogas
Industrial component evaluates the potential to develop a biogas-based industry for electricity, heat, CHP
or upgraded biogas. This is done by using waste water, high moisture solids, low moisture solids or a
combination of these. All technology pathways are based on simple and readily available technologies that
can be easily adaptable to remote rural areas.
The Transport sub-module is used to assess the viability of producing liquid biofuels for transport, namely
ethanol and biodiesel. The analysis builds on the results generated from the Natural Resources’
components in terms of feedstock availability and the crop budget. The tool covers ethanol and biodiesel.
In the ethanol sections the users can assess the potential for developing the ethanol industry in the
country. Likewise in the biodiesel section, the potential for developing the biodiesel industry is assessed.
The analyses generates results on the cost estimates for the production of the selected biofuel based on
feedstock origin, i.e. smallholder, combination smallholder/commercial or commercial, and according to
four predefined plant capacities, namely 5, 25, 50 and 100 million litres/year4. The results also consist of
information on economic feasibility and socio-economic parameters. In this component, the user has the
4
The selection of the predefined plant capacities is based on a review of relevant literature; please see the Transport
manual for further details.
5
option to include into the assessment a GHG emissions analysis that covers the whole supply chain of the
selected biofuels.
Another option for the user is to utilise the Pretreatment Calculator prior to using the Energy End Use
tools5. This allows the user to calculate the additional costs of pre-processing the biomass selected in order
to obtain the specific conditions required for the final biomass conversion for energy end use.
2 The Briquette Component

The Briquette Component is designed to assist the user in evaluating the potential to develop the
production of biomass briquettes to supply energy for heating and cooking in rural and urban households.
The boundary of the briquetting tool analysis is shown in Figure 2.
Figure 2: Biomass Briquette System for Rural and Urban Heating and Cooking
After completing the analysis, the user will be able to obtain information to better understand the most
viable feedstock that can be used for briquetting and the potential production scales that can be
considered for briquette production in the country. More specifically, the results will provide an indication
on: 1) the amount of biomass required to supply each of the pre-defined capacities; 2) the cost of
production and the investment cost associated with each of the options for briquettes production; 3) the
number of households that can be supplied with briquettes to meet their energy needs for heating and
cooking; and 4) the quantity of jobs that can be created (Figure 3). Financial indicators on Net Present Value
(NPV) and Internal Rate of Return (IRR) of briquette production are also generated to help the user assess
the financial viability of the different production systems.
5
The Pretreatment Calculator can be used prior to utilising the Energy End Use Tools. The exceptions are the Biogas
Community and Transport Tools, as these tools already include pretreatment.
6
Figure 3: Layout of the Briquettes Results Sheets
7
3 Terms and Definitions in the Briquettes Component
This section includes definitions of specific terms used in the Briquettes Component. It is important to
anticipate these definitions and consider them throughout the analysis, as to be able to interpret the
results correctly.
 Briquette is a compacting or densification process to increase the low bulk density of biomass to
high density (from 150-200 kg/m3 to 900 to 1300 kg/m3).
 Manual briquette technology is suitable for small-scale production capacity. The technology
consists of simple designs that are easy to construct, such as hand-powered screw extruder, lever
arm briquette press, car jack briquette press, etc. (Dahlman & Forst, 2001; Hite & Smith, 2011a,
2011b, 2011c, 2012; Lockard, n.d.).
 Screw press machine is a processing technology whereby the biomass is extruded continuously by
a screw through a taper die (S C Bhattacharya & Kumar, 2005; S.C. Bhattacharya, 2002; Grover &
Mishra, 1996; Poudel, Shrestha, & Singh, 2012; SNNPRs Investment Expansion Process, 2012;
Tumuluru, Wright, Kenney, & Hess, 2010; Tumuluru, Wright, Kenny, & Hess, 2010).
 Pretreatment of biomass: It is generally agreed that the size of biomass materials should be
between 6-8 mm size with 10-20% powdery component (< 4 mesh) and the moisture content
should not exceed 10% (Grover & Mishra, 1996). However, due to the diverse range of biomass
that can be used for briquetting and the particular properties associated with each type (e.g.
heating value, size, moisture content, and chemical composition), pretreatment is typically
required to ensure that the biomass conditions are suitable for briquette production. In this
context, pretreatment processes may involve drying to remove excess moisture, size reduction
(cutting, grinding) and pre-heating biomass (not higher than 300oC) to help loosen fibres in the
biomass and to soften its structure which reduces the wear of the screw press (Grover & Mishra,
1996). Pre-heating can also save up electrical energy required in briquetting. For example, in rice
husk at least 10% of energy is saved in conventional electric motor-driven briquetting machines
(S.C. Bhattacharya, 2002). Depending upon the type of biomass, three processes are generally
required. These involve the following steps:
o Sieving - Drying- Preheating - Densification - Cooling - Packing6
o Sieving - Crushing - Preheating - Densification – Cooling - Packing
o Drying - Crushing – Preheating - Densification – Cooling - Packing
 Briquette cooling: The surface temperatures from processing the briquettes in the hot screw press
can exceed 200°C. The briquette cooling takes place in the conveying belt which moves the
briquettes from production to storage. The cooling system is based on a perforated steel belt
conveyor for which a suitable length is required. The width of this open belt conveyor should be at
least 30% greater than the maximum length of the briquettes. The conveyor length should be a
minimum of 5 metres (Grover & Mishra, 1996). A hood is needed near the outlet of the machine
and part of the cooling conveyor to vent toxic fumes and keep the area safe (Grover & Mishra,
1996).
6
Note: Process A is used with sawdust. Process B is used with agro- and mill residues which are normally dry. These
materials are coffee husk, rice husk, groundnut shells, etc. Process C is used for materials like bagasse, coir pith,
mustard and other cereal stalks (Grover & Mishra, 1996).
8
 Briquette storage and packing: Briquettes are stacked length-wise and protected from water,
ideally in a shed (Grover & Mishra, 1996). Packing is required for briquette transportation and
selling in the market.
 The transformation efficiency of a briquette system relates to the densification conversion process
whereby biomass feedstock is converted from a low bulk density (80–100 kg/m3) to a high bulk
density (900 to 1300 kg/m3) briquette. In general, it has been found that when the biomass
feedstock moisture content is 8-10%, the briquettes will have 6-8% moisture (Grover & Mishra,
1996). Therefore, the mass does not change much compared to the volume.
 Skilled worker consists of personnel with particular skill or specialized experience, such as
machinery operators, supervisors and technicians.
 Unskilled worker consists of personnel with no special skill who support operations. Such workers
could be helpers or personnel carrying out tasks that can be learned easily, with a few days of
training.
4 Scope and Objective of the Briquettes Component

The aim of the Briquettes Component is to assess the feasibility to develop biomass briquette production. It
provides the user with the technical basis to perform an analysis for the production of briquettes at
different scales. The results of the analysis can be used to identify the viability of briquette production in
terms of the most appropriate feedstock, the financial viability of the different production systems, the
optimum production capacity and the socio and economic benefits that can be attained for each
production system.
The section below describes the flow of analysis and options within this component. The background
methodology for defining the biomass collection, biomass storage and financial analysis is described in
detail in the Annex.
9
Figure 4: Rapid Appraisal Tool for Heating and Cooking - Briquettes Component
5 Running the Briquette Component
The flow of analysis within the Briquettes Component and the inter-linkages it has with other components is
depicted in Figure 5. The user has the choice to select the components of analysis in a different order or
even omit some components. It is, however, strongly recommended that the user follows the order and
flow of analysis as described below, given that the Briquettes Component relies on the information
generated in the Natural Resources module and information can be cross-referenced with other modules to
contextualize the results of the analysis. The results of this component are essential for the
comprehensiveness of the analysis. When interpreting the results, the user should take into account all
relevant factors, particularly aspects related to food security, agricultural trade and the sustainable use of
natural resources.
10
Figure 5: Briquettes Component: Flow of Analysis and Inter-linkages with BEFS RA Modules and
Components
11
The user navigates step by step through the options and is asked to input the necessary data to obtain final
results. When the required data are limited or unavailable, then the default values provided by the tool can
be utilised. The navigation buttons are placed on the top and bottom of each sheet, indicating the next step
with the button “NEXT>>” and allowing the user to return to a previous section with the “<<BACK” button.
The following sub-chapters describe each step of the analysis, using an example from the Agriculture
Residues Component to produce the briquettes. All input parameters are based on a generic situation.
5.1 Step 1: Energy demand

The first step is to enter the market price as well as the current energy consumption of briquette,
fuelwood, charcoal, kerosene and LPG. This must be done for both rural and urban households. These
values are used to estimate the energy expenditure and briquette consumption equivalent of consumers.
To run this analysis, the user has to enter data on:
- Market price of each energy type in rural households (Figure 6, label 1)

- Energy consumption of each energy type in rural households (Figure 6, label 2)
- Market price of each energy type in urban households (Figure 6, label 3)
- Energy consumption of each energy type in urban households (Figure 6, label 4)
1 2 3 4
Figure 6: Energy Demand in Rural and Urban Areas
For this example, the values shown in Figure 6 were used to carry out the analysis.
12
5.2 Step 2: Defining the feedstock

Step 2.A Selection of the feedstock
The user will:

1. Select the crop(s) and the residue associated with the crop from the dropdown menu. The list
includes 15 key food/cash crops and two types of wood processing residues. Up to four residues
can be analysed at the same time (Figure 7, label 1).
3
5
Figure 7: Feedstock Selection
2. Enter data on feedstock available (t/year) and yield (t/ha) of the selected crop residues (Figure 7,
label 2). This information is generated in the Natural Resources module.
3. The moisture content (%) or average percentage of moisture content of the selected crop residues
is automatically generated from the technical database in the tool (Figure 7, label 3).
For this example, the following were selected: Feedstock 1 “Cassava stalk”, Feedstock 2
“Maize husk”, Feedstock 3 “Coffee husk” and Feedstock 4 “Oil palm empty bunches” (Figure
7).
Step 2.B Feedstock price (USD/t)
The user has two options for determining the feedstock price:
A. If there is a current price in the country for this feedstock, the user clicks on the “Market Price
(transport excluded)” (Figure 7, label 4) and directly inputs the price of the selected feedstock
(USD/t) in the corresponding cell.
13
B. If there is no current price for this feedstock, the user can estimate the feedstock price by
clicking on the “Use Price Definition
Calculator” and selecting the “Price
Calculator” (Figure 7, label 5).
The user will get a “warning” before continuing

with the use of the calculator, and the user will
need to enter:
1. The wage for both unskilled and skilled labour in “Labour” section in unit of USD per person-hour.
2. The working hours and price of diesel in the corresponding lines under “Feedstock collection”.
The “Price Calculator” (Figure 8) assists the user in estimating the potential feedstock price based on the
source and collection method of the feedstock.
Figure 8: Feedstock Price Calculation based on the Collection Method and Source
To run the price calculator, the user will need to:
1. Identify the biomass source from one of the following options (Figure 8, label 1):
- Agriculture residues spread in the field
- Agriculture residues collected from the field
- Agriculture residues from food processing plant
- Forestry
14
- Forestry and plantation residues

- Residues from wood industry
- Dedicated wood energy plantation
As a reference, Table 1 summarizes the biomass sources that can be used for the production of briquettes.
2. Select the biomass collection method from the Guidance: The collection method can
following options (Figure 8, label 2): be identified based on similar practices
currently applied in the country.
- manual
- semi-mechanized
- mechanized
3. Enter the labour requirements (person-hour per

Note: The type of labour and diesel
hectare) and the fuel needs (litres per hour) requirements will depend on the
associated with the selected biomass collection collection method: manual, semi-
mechanized and mechanized.
method (Figure 8, label 3). To return to the previous
section, the user must click on the “<<BACK Data
Entry” button.
The calculator will automatically generate a feedstock price (Figure 8, red box), and this value is
transferred to the “Data Entry Needs” worksheet for further calculation.
4. The user will need to carry out similar steps for each feedstock chosen.
Table 1: Specific Feedstock that can be Used in the Briquette System

Source Specific feedstock that can be used
Agricultural field residues cassava stalk, coconut frond, cotton stalk, maize stover, millet straw, oat straw, oil palm
frond, rice straw, rye straw, sorghum straw, soybean straw, sugar cane tops & leaves, wheat
straw
Agriculture residues from cacao pods, coconut husk & shell, coffee shell/husk, cotton hulls, groundnut husk, maize cob
industrial processing & husk, oil palm empty bunches, olive pruning/pressing residue, rice husk, sugar cane bagasse
Forestry leaves, limbs, etc.
Forestry and plantation residues leaves, limbs, stump, roots, etc.
Residues of wood industry saw dust
Dedicated energy plantations Acacia spp., Cunninghamia lanceolata, Eucalyptus spp., Pinus spp., Populus spp. (poplars) and
Salix spp. (willows)
For this example, the selected Feedstock 1 “Cassava Stalk” is assumed to be sourced from
“agricultural residues spread in the field” and the collection method is “semi-mechanized”. The
number of person-hours for skilled workers (machine operators) is 1 and for unskilled workers is
3, and the diesel consumption of the machine is 2 litres per hour. Using the information that
manual labour works 8 hours per day and machinery works 16 hours with a diesel price of 1 USD
per litre, a proxy price of the feedstock is calculated at 0.17 USD per/t (Figure 8).
Before proceeding with the analysis, the user can load the default values for running this part of the
component by clicking on “Load Default Values” as shown in Figure 9, label A.
15
1
2
3
4
Figure 9: Chemical Binder and Feedstock Storage Cost
Step 2.C Chemical Binder Guidance: According to literature,

The user must determine if a chemical binder7 is used in the binder is typically used in manual
briquette production process. production. Screw press
technologies typically do not require
a binder.
If the user selects “yes”, the user will need to:
1. Select the type of binder from the following options
(Figure 9, label 1):
- Cassava flour
- Maize flour
- Wheat flour
2. Enter the binder cost (USD/tonne) for all feedstock (Figure 9, label 2).
Step 2.D: Feedstock storage cost (USD/t)
Step 2.D.1 The user can enter the existing prices of storage of agricultural products in the country
as a proxy. The price should be entered in the respective cell for each feedstock (USD/tonne). If this
information is not available, then the user should go to the next step.
Step 2.D.2 The user can determine a proxy for this value. The user will need to do the following:
1. Identify a type of feedstock storage likely associated with the conditions in their country
from the options presented in Table 2.
2. For the selected storage option, look up the global building cost provided in Table 2.
3. Enter the proxy value (USD/tonne) in the respective cell for each feedstock.
7
Guidance reference: Ferguson, 2012; GVEP International, 2010; Kaliyan & Morey, 2010; Tumuluru, Wright, Kenney, et
al., 2010; Kaliyan & Morey, 2010; Tumuluru, Wright, Kenney, et al., 2010.
16
Note that this value will be used as a proxy for the storage cost for both the feedstock, i.e. raw material,
and the product, i.e. briquette.
Table 2: Estimated Cost of Storage
Estimated Cost of Storage Unit Min Average Max

Enclosed structure with crushed rock floor USD/tonne 10 12.5 15
Open structure with crushed rock floor USD/tonne 6 7 8
Reusable tarp on crushed rock USD/tonne n/a 3 n/a
Outside unprotected on crushed rock USD/tonne n/a 1 n/a
Outside unprotected on ground USD/tonne n/a 0 n/a
Source: (EPA, 2007)
For this example, all feedstock are stored on crushed rock and
unprotected. Therefore, the cost of storage is 1 USD/tonne. (User inputs
the cost in the corresponding cells as shown in Figure 9, label 3).
Step 2.D.3 In order to calculate the storage capacity needs, the user needs to click on the “Storage
Calculator” (Figure 9, label 4). This will take the user to the Biomass Storage Calculator (Figure 10).
In this worksheet, the user will need to:
1. Select the harvesting month(s) of the crop (Figure 10, label 1).
2. Enter the biomass safety stock rate (%). This is the percentage of biomass needed to secure
continuous supply of feedstock to deal with uncertainty in production due to seasonal
availability, flood, drought, and other factors. This stock rate % is used to estimate the
storage capacity (Figure 10, label 2).
3. Click on “Calculate” (Figure 10, label 3) to automatically compute the amount of maximum
storage capacity required (tonnes) and the minimum safety storage (tonnes per month) for
each of the pre-defined capacities (Figure 10, label 4).
4. Click “OK”, to return to the Data Entry Needs sheet (Figure 10, label 5).
5. Repeat the same steps for all feedstock.
1
2
4
3
5
Figure 10: Feedstock Storage Calculator
17
For this example, Feedstock 1 “Cassava Stalk” is harvested in March and

September. As a result, the storage capacity required is 5 tonnes for 4 kg/h
production capacity. The minimum safety feedstock to store is 1 tonne per
month.
5.3 Step 3: Production cost and financial parameters

General inputs required to run the operations are shown in Figure 11. The user will need to provide data
on:
Figure 11: General Inputs
1. Utilities cost: the price of water (USD/m3) and electricity (USD/kWh).

2. Labour cost (USD/person-hour): the labour rate for unskilled and skilled workers (USD per employee
per hour). These parameters are required to calculate the feedstock price (as explained in Step 2.B)
and the labour cost of the briquetting production process.
3. Feedstock collection: these parameters are required to calculate the feedstock price as explained in
Step 2.B. The user enters the hours of labour required for manual labour, hours of labour required for
running the machinery and the price of diesel.
4. Price of briquettes (USD/kg): The user will also need to provide the current market price for briquette
in both rural and urban areas. If this information is not available, then the price of charcoal can be
used as proxy. This data is used to analyse the total potential revenue of the briquette system for each
pre-defined production capacity.
5. Transportation cost of feedstock (USD/t/km): cost of transportation of
feedstock from the collection point to the briquette plant. The user will Guidance: This can be
need to: based on unprocessed
agricultural goods.
- Identify the current methods of transportation of moving
agriculture commodities within the country.
18
- Define the current transportation prices associated with the transportation method identified
above in unit of USD per tonne per km.
Guidance: If the method of transportation is by person or bike, then it is recommended that the
user estimates the cost by using the cost of labour per hour, working time, the amount of
material that can be transported and the approximate kilometres that can be travelled under the
selected method as given in the following equation:
Transportation cost (USD/tonne/km)
= Hourly wages (USD/hour/person) x Working time (hours)
Transportation distance (km) x Feedstock transport (tonne/person)
Alternatively, the user can include this cost in the collection cost of feedstock by adding this to
the number of workers in Step 2.B (estimate price of feedstock) and then inputting zero costs for
the transportation of feedstock from the collection point to the plant.
6. Transportation cost of briquettes (USD/t/km): cost of

transportation of briquette from plant to market. The user will Guidance: This can be
need to: based on processed
- Identify the current methods of transportation of moving agricultural goods.
- Define the current transportation prices associated with the transportation method identified
above in unit of USD per tonne per km.
7. Operation parameters of the briquette system: The user enters Guidance: For manual
the operating hours per day and operating days per year of the briquette production,
the maximum operating
briquette system. These parameters are used to estimate the
hours per day should be
annual briquette production (tonnes per year). 8 hours.
8. Other Costs (%): The user enters the percentage of:
- Plant overhead,
- Maintenance,
Guidance: The user
- General and administrative and
determines the briquette
- Safety storage rate of briquette products. safety stock rate to
These parameters are used to estimate the production costs of ensure sufficient supply of
briquette. briquette in the market.
9. Financial parameters: The user identifies the values for the
following financial parameters:
- Discount rate (%),
- Loan ratio (%),
- Loan interest rate (%),
- Loan term (years) and
- Plant Cost Index.
The plant cost index data for equipment cost is obtained from technical literature and based on past
technical and economic conditions. Therefore, the Intratec Chemical Plant Construction Index (IC), a
dimensionless index used as a proxy to update the capital cost of a chemical plant, which accounts for price
changes due to inflation/deflation and economic conditions, is applied to the BEFS RA tool. This index is
freely updated and available on (http://base.intratec.us/home/ic-index).
For this example, the values shown in Figure 11 were used to carry out the analysis.
19
5.4 Step 4 (Optional): Calculation of the production

cost of briquettes Note: This section also shows the budgets for
calculating the processing costs. These
calculations are done automatically using the
After completing all of the data entries required in Steps 1 to information entered by the user in the
3, the user clicks on the “Production Cost” button in the Data previous steps and can be reviewed if needed
(see section 7.1 for more details).
Entry Sheet (Figure 12, red box).
Figure 12: Production Cost Calculation
This will take the user to the budget processing section for the selected feedstock (Figure 13).
2 3
Figure 13: Processing Costs of Briquettes
In this worksheet, the user will need to enter additional data in the white cells, specifically on:
20
1. Transformation efficiency: the typical transformation efficiency is assumed to be 95% mass basis. The
user, however, can enter different transformation efficiency values to assess the effect that this
efficiency can have on the amount of feedstock consumption and production cost of briquettes (Figure
13, label 1).
2. The transportation distance of feedstock to

briquette plant: The user identifies an estimated Guidance: The transportation distance depends on
transportation distance that will be required the availability of biomass in a particular area and
the amount of biomass required for each production
to transport the feedstock in kilometres for capacity. The manual and small-scale plants use less
each briquette production capacity (Figure 13, biomass compared to the medium and large-scale
label 2). ones. Therefore, the distance of transportation could
be shorter. If the availability of biomass in that area
is high and sufficient enough to supply for all
production scales of the briquette plants, then the
users can input the same transportation distance of
3. The transportation distance of briquette
feedstock for all production scales.
products to market: The user identifies an
estimated transportation distance that will be
required to transport the briquettes to market in
kilometres for each briquette production capacity
(Figure 13, label 3). Note: If the availability of briquettes Guidance: The large-scale plant can supply briquettes
in an area is high and sufficient enough to supply for all to many markets that are further away, and may
require longer transportation distances compared to
production scales of the briquette plants, then the user
other scales.
can input the same transportation distance for all scales
of production.
For this example, the default values are utilised to carry out the analysis (Figure 13).
6 Assumptions and Limitations of the Briquettes Component

Before starting the analysis, the user should become familiar with the assumptions and limitations of the
tool and take them into consideration during the analysis and most especially when interpreting the results.
The limitations of the Briquettes Component are:
1. Manual briquette production is set at 4 kg per hour.

2. Mechanized screw press is set at 40,400 and 3,000 kg per hour.
3. Optimum moisture content of the raw material is 8-9%.
4. Particle size must be 6-8 mm.
5. The chemical binders include only cassava flour, maize flour or wheat flour.
6. The cost of the external heating system is excluded.
7. The cost of pretreatment is excluded.
8. Business lifetime is 20 years for financial analysis.
The details of key assumptions and calculation equations are presented in the Annex.
21
7 The Results of the Briquettes Component
7.1 Overview of the production cost calculations (optional)

After the user inputs all required data (Steps 1 to 3), then the user has the option to review the detailed
production cost as shown in Figure 14. There are four main sections in this worksheet as explained below.
- PART 1 (Figure 14, label 1) shows the distribution of production cost along the following categories:
inputs, labour, transportation of feedstock, storage, investment, plant overhead, general and
administrative cost, loan interest, and income tax. The total production costs (USD/year) of the four
briquette production capacities (4, 40, 400 and 3,000 kg per hour) are also summarized.
- PART 2 (Figure 14, label 2) shows the unit cost of briquette (USD/kg of briquette) for each of the
production capacities.
- PART 3 (Figure 14, label 3) summarizes the loan details, e.g. loan amount, loan interest, annual loan
payment, etc., for financial analysis.
- PART 4 (Figure 14, label 4) the “Financial Analysis” buttons will open the worksheet with the detail
on the financial analysis for each production capacity for both rural and urban markets.
22
Figure 14: Detail of Production Costs of Briquettes by Production Capacity
For Cassava stalk example, the total production cost of manual (4 kg/h) is 551 USD per year. The
unit cost of briquette is 0.057 USD/kg. The average loan interest is 22 USD/year.
For other pre-defined capacities refer to Figure 14.
23
7.2 The summary of results by feedstock

Results for the Briquettes Component are divided along three main categories: Production Cost and
Investments; Plant Operating; and Financial Analysis.
1. The user first selects the feedstock from the dropdown menu that he/she wants to review (Figure
15, label 1). The results for that specific feedstock will be generated.
2. The production cost and investments results are presented as follows:
 Cost of production and transportation of briquettes (USD/kg) (Figure 15, label 2). The user
can compare the production cost to the market price (rural or urban) by selecting either or
both options.
 Total investment cost (USD) of the briquette system by production capacity (Figure 15,
label 3).
1
4
2 3
Figure 15: Production Cost and Investment Results
For this example, Feedstock 1 “Cassava Stalk”, the total production cost included the
transportation cost of both manual production at 4 kg/h (Size 1) and mechanized production at
3,000 kg/h (Size 4), which range between 0.06-0.07 USD/kg and 0.09-0.12 USD/kg, respectively.
These unit costs are lower than the rural market price of 0.5 USD/kg and the urban market price of
0.6 USD/kg. Therefore, both plants are attractive investments that are feasible. The total
investment cost of Size 1 and Size 4 are 2,626 USD and 2,553,410 USD, respectively (Figure 15).
3. The technical and operating results are presented as follows:

 Biomass required to run the selected capacity (tonnes per year) (Figure 16, label 1).
 Number of briquette plants that can be developed for each capacity based on biomass
availability (Figure 16, label 2).
 Biomass area requirement to produce briquettes (hectare) (Figure 16, label 3).
 Number of households that can be supplied by the system (Figure 16, label 4).
24
 Total job creation by the implementation of the pre-defined briquette systems (Figure 16,
label 5).
1 4
3
2
Figure 16: Operating Results
In the example Feedstock 1 “Cassava Stalk”, the feedstock available is 2,500 tonnes per year, which is
sufficient enough to supply for Size 1, Size 2 and Size 3 production capacities. But, it is not sufficient
enough to supply for the Size 4 capacity. In accordance with the feedstock availability, there can be 247
potential briquette plants at 4kg/h capacity (Size 1) which require 1 hectare of area of feedstock. In turn,
this would supply briquettes to 6 households in rural areas or one household in an urban area.
Moreover, the potential job creation from a briquette plant of 4kg/h capacity (Size 1) is one job for
feedstock collection. There is no job creation for the briquette processing plant, since the owner is the
worker (Figure 16).
4. The financial analysis (before tax return) results are presented as follows:
 Net Present Value (NPV) (Figure 17, label 1)
 Internal Rate of Return (IRR) (Figure 17, label 2)
1 2
Figure 17: Financial Analysis Results
For this example, Feedstock 1 “Cassava Stalk”, the NPV and IRR of Size 1 and Size 4
are positive for both rural and urban markets, while this is not true for Size 2 and 3
(Figure 17).
25
The user can save and print the results in PDF format by using “Create a PDF report” and following the
instructions (Figure 15, label 4).
The results aim to answer the following questions:

 What is the production cost and investment cost of briquettes?
 How much biomass is required to supply each of the pre-defined capacities?
 How many households can be supplied with energy for heating and cooking?
 How many jobs can be created by developing this production system?
 What are the Net Present Value (NPV) and Internal Rate of Return (IRR) of briquette production?
For this example, the information generated indicates that based on the available cassava
stalk, Sizes 1 through 3 for briquette plants are possible (as shown in Figure 16). However,
only the briquettes from Plant Size 1 can feasibly supply both rural and urban markets.
7.3 The summary of comparative results

In this section, the user can compare the results across the various feedstock that were evaluated.
1. The user first selects the feedstock, by clicking on it, that he/she wants to review. The results for
that specific feedstock will be generated.
2. Comparison results are presented on:
 Production costs according to feedstock (USD/kg) (Figure 18, label 1)
 Number of briquette plants by production capacity (Figure 18, label 2)
 Number of jobs creation by production capacity (Figure 18,
label 3) Guidance: These results can
3. To assess the financial analysis, the user can select rural or urban help identify the type of
feedstock and production
markets or both. Depending on this selection, a comparison of the scale that is most viable
financial results (before taxes) is generated for: should be promoted for
 NPV in rural areas (Figure 18, label 4) briquette production.
 NPV in urban areas (Figure 18, label 5)

 IRR in rural areas (Figure 18, label 6)
 IRR in urban areas (Figure 18, label 7)
The user can save and print the results in PDF format by using “Create a PDF report” and following the
instructions (Figure 18, label A).
26
1 2
Figure 18: Layout of Comparative Results
For this example, the production costs for the four feedstocks are similar for all
production capacities. Moreover, only Plant Size 1 and 4 have a positive NPV and
IRR for both rural and urban markets (Figure 18).
It can be concluded that:

All feedstock are feasible and available for briquette production for only Plant Size
1. Therefore, policymakers can promote all four feedstocks for briquette production
(Size 1) in rural and urban areas.
27
8 Annex
8.1 Methodology and outputs

This section describes the methodologies integrated in the Briquettes Component. It also includes a
description of the equations which support the analysis. The equations are not visible to the user, but their
structure and content might be important for those who will update them and/or work on the
improvement of the tool.
8.1.1 Cost calculation of required inputs

The detailed calculation used in the production cost of briquette for the pre-defined capacities: 4 kg/h, 40
kg/h, 400 kg/h and 3000 kg/h. Total inputs cost consist of the feedstock/biomass cost, chemical binder cost,
water, and electricity consumption. The equations for calculation are presented in Table 3.
Table 3: Inputs Cost Equations

Item Equation and Assumption Remark
Briquette Products (BP) BP = Capacity (kg/hr) x Operating hours per year The maximum operating days
(tonnes per year) Where: per year of manual briquette
The pre-defined capacities are: production are 300 days and
o Manual scale 4 kg/h 8 hours per day.
o Mechanized small scale 40 kg/h
o Mechanized medium scale 400 kg/h
o Mechanized large scale 3000 kg/h
Operating hours per year = Operating days per year x Operating
hours per day
Quantity of Feedstock QF = BP/transformation efficiency The transformation efficiency
(tonnes per year) Where: default value is 95%, but the
QF is Quantity of feedstock (tonne per year) user can input other values
BP is Briquette products (tonne per year) directly.
Chemical Binder CB = BP/BS The specific consumption of
(tonnes per year) Where: binder is 1 kg of binder per 10
CB is Quantity of chemical binder (tonne per year) kg of briquettes
BP is Briquette products (tonne per year) (Ferguson, 2012).
BS is Specific consumption of binder (kg of briquette/kg)
Water Consumption WC = BP *1000/WS The default value of WS is
3
(m per year) Where: 4,667 (SNNPRs Investment
3
WC is Water consumption (m per year) Expansion Process, 2012).
BP is Briquette products (tonne per year)
3
WS is Specific water consumption (kg per m )
Electricity Consumption EC = BP*ES The default value of ES is 93.4
(kWh per year) Where: (Tumuluru, Wright, Kenney,
EC is Electricity consumption (kWh per year) et al., 2010).
BP is Briquette products (tonne per year)
ES is Specific electricity consumption (kWh per tonne)
Total Inputs Cost TIC = (QF x Cf) + (CB x Cb) + (WC x Cw) + (EC x Ce)
(USD per year) Where:
TIC is Total inputs cost (USD per year)
QF is Quantity of feedstock (tonne per year)
CB is Quantity of chemical binder (tonne per year)
3
WC is Water consumption (m per year)
EC is Electricity consumption (kWh per year)
Cf is unit cost of feedstock (USD per tonne)
Cb is unit cost of chemical binder (USD per tonne)
3
Cw is unit cost of water (USD per m )
Ce is unit cost of electricity (USD per kWh)
28
8.1.2 Cost calculation of required labour

The equations and assumptions for calculating the labour and miscellaneous cost based on the briquette
production capacity are shown in Table 4.
Table 4: Labour and Miscellaneous Cost Equations

Number of unskilled workers Manual scale is 0 persons (owner is worker) (Ferguson, 2012; Poudel et al., 2012; SNNPRs
Mechanized small scale is 6 persons Investment Expansion Process, 2012; Young
Mechanized medium scale is 64 persons & Khennas, 2003)
Mechanized large scale is 15 persons
Number of skilled workers Manual scale is 0 persons (owner is worker) The assumptions are made based on the
Mechanized small scale is 2 persons number of unskilled labourers as related to
Mechanized medium scale is 12 persons production capacity (SNNPRs Investment
Mechanized large scale is 20 persons Expansion Process, 2012).
Unit cost of unskilled worker Input data by user in “Data Entry Needs”
(USD/person/hour)
Unit cost of skilled worker Input data by user in “Data Entry Needs”
(USD/person/hour)
Operating hours per year Operating hours per year = Operating days per year x Operating hours per day
Total unskilled worker cost Unit cost of unskilled worker x number of unskilled workers x operating hours per year
(USD per year)
Total skilled worker cost Unit cost of skilled worker x number of skilled workers x operating hours per year
(USD per year)
Miscellaneous cost* 25% x (Total unskilled worker cost + Total skilled worker cost)
(USD per year)
Total labour cost Total Unskilled worker cost + Total skilled worker cost + Miscellaneous cost
(USD per year)
*Note: A miscellaneous cost consists of labour benefits, health & life insurance, operating supplies and/or laboratory
charges.
29
8.1.3 Cost calculation of required transportation

The calculation equations for the transportation cost are shown in Table 5.
Table 5: Transportation of Feedstock and Briquette Products Cost Equations

Transportation of feedstock Unit transportation cost x Transportation distance x QF QF is calculated in Table 3
(collecting point to plant) Input by user in “Data Entry Needs” (USD/tonne/km)
(USD per year) Input by user in “COST_RES#” (km)
Transportation of briquette Unit transportation cost x Transportation distance x BP BP is calculated in Table 3

(plant to market) (USD per Input by user in “Data Entry Needs” (USD/tonne/km)
year) Input by user in “COST_RES#” (km)
8.1.4 Cost calculation of storage

The calculation equations of storage cost are as shown in Table 6.
Table 6: Storage Cost Equations

Storage cost of feedstock Unit storage cost x Storage Capacity The storage cost is input by
(USD per year) the user in the processing
budget section (USD/tonne).
Storage capacity The storage capacity is calculated by the storage calculator Result of storage calculator
(tonnes/year)
Storage cost of briquette Unit storage cost x Storage Capacity Briquette product storage
products (USD per year) input by the user
(USD/tonne)
Storage capacity of briquette Briquette stock rate x BP BP is calculated in Table 3

products (tonnes/year)
30
8.1.5 Fixed cost calculation

Fixed costs consist of equipment cost, building cost and installation cost. This step presents the calculation
equations of fixed costs and its depreciation cost as shown in Table 7.
Table 7: Fixed Cost Equations

Equipment cost (EC) EC (base year) = Unit equipment cost x BP x 20 years Unit equipment cost in Table 14
(USD) BP is calculated in Table 3
EC at current period = EC (base year) x [Plant Cost Index
(current period)/Plant Cost Index (base year)] Plant cost index (current period) input
by the user
Building cost (BC) BC (base year) = Unit Building cost x BP x 20 years Unit Building cost in Table 14
BC at current period = BC (base year) x [Plant Cost Index
by the user
Installation cost (IC) IC (base year) = Unit Installation cost x BP x 20 years Unit Installation cost in Table 14
IC at current period = IC (base year) x [Plant Cost Index
by the user
Total investment Equipment cost + Building cost + Installation cost Business lifetime is 20 years
(USD)
Equipment depreciation Equipment cost divided by business life time Straight line method of depreciation
(USD per year) calculation
Building depreciation Building cost divided by business life time Straight line method of depreciation
Installation depreciation Installation cost divided by business life time Straight line method of depreciation
Total depreciation Equipment Depreciation + Building Depreciation Straight line method of depreciation
(USD per year) + Installation Depreciation calculation
Maintenance cost Percentage of maintenance x Total depreciation Share of maintenance input by the
(USD per year) user
Total of Fixed cost Total depreciation + Maintenance cost
(USD per year)
Note: The plant cost index is used to update equipment, building and installation costs to the current period.
Please visit this website for further information: http://en.wikipedia.org/wiki/Chemical_plant_cost_indexes.
The assumption in this tool is that plant cost index can be applied to any plant type and size. It is providing an
acceptable proxy to update the investment costs.
31
8.1.6 Calculation of other costs

The plant overhead is defined as a charge to the production for services, facilities and payroll overhead. The
general and administrative costs comprise of rents, insurances, managerial, administrative and executive
salaries. The equations for calculating the plant overhead, general and administrative cost, average loan
interest payment and income tax are as shown in Table 8.
Table 8: Other Costs Equations

Plant Overhead Percentage of plant overhead x (Total labour cost + Percentage of plant overhead is
Maintenance cost) input by the user. The default
(USD per year) value is 5%.
General and Administrative Percentage of general and administrative cost x (Total Percentage of general and
Cost inputs cost + Total labour cost + Maintenance cost + administrative cost input by the
Plant overhead) user. The default value is 5%.
(USD per year)
Average Loan interest payment Loan amount = Loan ratio (%) x Total investment cost PMT is a financial function in
(USD per year) Microsoft Excel for calculating
Loan payment (USD/month) = PMT([Loan interest the payment for a loan based on
rate/12],[12x Loan term], Loan amount) constant payments and a
constant interest rate.
Annual loan payment = Loan payment (USD/month) x 12
months
Total loan payment = Annual loan payment x Loan terms
Loan interest payment = Total Loan payment - Loan

amount
Average loan interest payment = Loan interest payment

divided by business lifetime
8.1.7 Total production cost and unit cost of briquette calculation

The calculation equations of the total operating costs, total fixed costs, other total costs, total annual
production cost of briquettes and unit production cost per kg are shown in Table 9.
Table 9: Total Production Cost Equations

Total Operating Costs annual inputs cost + annual labour cost + annual
(USD per year) transportation cost + annual storage cost
Total Fixed Costs depreciation fixed cost +annual maintenance cost
(USD per year)
Total Other Costs annual plant overhead + annual general &administration
(USD per year) cost + annual loan payment
Total Production Cost Total Operating Costs + Total Fixed Costs + Total Other
(USD per year) Costs
Production cost per kg Total Production Cost divided by briquette production Briquette production is
calculated in Table 3
32
8.1.8 Briquette demand calculation
This step details the calculation equations carried out to determine the energy demand in briquette
equivalents. Note that the conversion factors have taken into consideration the energy efficiency gains of
the end use (i.e. stove).
Table 10 presents the calorific value and the assumptions used in stove efficiency to calculate the useful
energy of briquettes when compared to other fuels. For example, burning briquettes in a 50% efficiency
stove yields 7.7 MJ/kg of useful energy to the end user (Table 10 - line 1, column 3). Comparing the useful
briquette energy with low efficiency fuelwood stove (efficiency 20%), indicates that the use of fuelwood
yields only 16% of the useful energy of briquettes. That is 6.11 kg of fuelwood are needed to provide the
useful energy equal to 1 kg of briquette (Table 10 - line2, column 4). Similar assessments for charcoal,
kerosene and LPG are presented below:
Table 10: Comparison of Briquette with Other Fuels

Calorific Value (CV) Stove efficiency Useful energy Conversion factor (CF)
MJ/kg % MJ/kg kg of Fuel*
Briquettes 15.4 50% 7.7 1.00
Fuelwood 6.3 20% 1.3 6.11
Charcoal 27.0 25% 6.8 1.14
Kerosene 44.0 55% 24.2 0.32
LPG 49.0 60% 29.4 0.26
Note: *compared to energy of briquette 1 kg
Source: Young & Khennas, 2003
The conversion factor to calculate the briquette consumption equivalent is therefore the values of 6.11 kg
of fuelwood, 1.14kg of charcoal, 0.32kg of kerosene and 0.26kg of LPG compared to the energy of 1 kg of
briquette (Table 10).
The equations for calculating the briquette demand equivalent are presented in Table 11.
Table 11: Briquette Demand Equations

Annual Fuel i consumption AFi = Fuel i x 365 /1000 Fuel i (kg/day) is input by the user
(Tonnes per year)
Where:
AFi = Annual fuel i consumption
Fuel i = fuel i consumption (kg/day)
i = Briquette, fuel wood, charcoal, kerosene and LPG
Annual briquette consumption ABe = ∑(AFi/CFi) Table 10

equivalent (tonnes per year) Where: CF of briquette = 1 kg/ kgbriquette
ABe = Annual briquette equivalent CF of fuel wood =6.11 kg/kgbriquette
AFi = Annual fuel i consumption CF of charcoal = 1.14 kg/kgbriquette
CFi = Conversion factor of fuel i CF of kerosene = 0.32kg/kgbriquette
i = Briquette, fuel wood, charcoal, kerosene and LPG CF of LPG = 0.26 kg/kgbriquette
(Young & Khennas, 2003)
Energy expenditure of fuel i EEi = Unit price fuel i x AFi x 1000 Unit price fuel i (USD/kg) is input by
(USD per year) the user
Where:
EEi = Energy expenditure of fuel i
33
Unit price fuel i (USD/kg)

AFi = Annual fuel i consumption
Competitive price of briquette CPb = (∑EEi)/ ABe
(USD per kg)
Where:
CPb = Competitive price of briquette
EEi = Energy expenditure of fuel i
ABe = Annual briquette equivalent
8.1.9 Project revenue calculation

The equations for calculating the project revenue are presented in Table 12.
Table 12: Project Revenue Equations

Potential revenue Briquette products x Market Price of briquette x 1000 Briquette products (tonnes per
year) in Table 3
(USD per year)
Market price of briquette (USD/kg)
is input by the user
34
8.1.10 Briquetting technologies

Table 13: Briquetting Technologies Comparisons
Briquetting Technologies Screw Press Piston Press Roller Press Pellet Mill Agglomerator Manual
Production capacity (kg/hr) 150 kg/hr 200 - 2,500 kg/hr 900-1,500 kg/hr 200 - 8,000 kg/hr No information 6 kg/hr
Optimum moisture content of the raw material 8–9% 10–15% 10–15% 10–15% No information up to 80%
Particle size Smaller Larger Larger Smaller Smaller-powder Smaller-fibre
Wear of contact parts High Low High High Low Low
Output from machine Continuous In strokes Continuous Continuous Continuous In strokes
Specific energy consumption (kWh/t) 36.8-150 37.4-77 29.91-83.1 16.4-74.5 No information No electricity
Through puts (t/hr) 0.5 2.5 5.0-10.0 5 No information No information

3 3 3 3 3
Density of briquette 1-1.4 g/cm 1-1.2 g/cm 0.6-0.7 g/cm 0.7-0.8 g/cm 0.4-0.5 g/cm No information
Maintenance Low High Low Low Low Low
Combustion performance of briquettes Very good Moderate Moderate Very good No information Moderate
Carbonization of charcoal Makes good charcoal Not possible Not possible Not possible Not possible Yes
Suitability in gasifiers Suitable Suitable Suitable Suitable Suitable No information
Suitability for co-firing Suitable Suitable Suitable Suitable Suitable Suitable
Suitability for biochemical conversion Not suitable Suitable Suitable Suitable No information No information
Homogeneity of densified biomass Homogenous Not homogenous Not homogenous Homogenous Homogenous Homogenous
Cost (USD) 1,350 20,000-30,000 14,000-19,000 No information No information 150

Source: Tumuluru, Wright, Kenny, et al., 2010
35
8.1.11 Database for financial analysis

The database for the financial analysis of briquette production is presented in Table 14.
Table 14: Investment Cost of the Briquette System
Tonne of Briquette (production per year)

Capacity of Briquette
Unit
Production
<20 <200 <2000 <20,000
Investment Cost of
USD 1,000 5,000 50,000-100,000 2,200,000
Equipment
Equipment Lifetime Years 5 10 15 20
Estimate Equipment Cost

USD per tonne 10 3 3.3 6
(per t of briquette)
Equipment 1 or 2 manual machines e.g. lever Motorized machines that are fabricated Motorized machines that are imported, Large-scale industrial machinery,
extruder/ manual screw extruder locally, e.g. Electric screw extruder e.g. Roller press/ large(flywheel) piston imported, e.g. 8 t/h hydraulic pellet
Single Drum Kilns Sun-drying/solar driers Sun-drying / Flash drier press
Sun-drying Accelerated drying
Building and Land Often in entrepreneurs house and Can do at entrepreneurs residence or Dedicated factory needed. Large centralized factory,
garden, in a large garden, Approximate 2 acres of land, e.g. biomass storage, Briquette
e.g. biomass storage, briquette storage, e.g. biomass storage, briquette storage, e.g. biomass storage, briquette storage, storage, briquetting plant, office
briquetting plant briquetting plant briquetting plant building
Assumption Estimate at 20% of Total investment Estimate at 20% of Total investment Estimate at 44% of Total investment Estimate at 44% of Total investment
cost cost cost cost
USD per tonne 2.50 0.63 2.62 4.32
Installation Cost Assumption Estimate at 10% of equipment cost Estimate at 10% of equipment cost Estimate at 10% of equipment cost Estimate at 10% of equipment cost
USD per tonne 1.00 0.25 0.33 0.55
Estimated Total USD per tonne

13.50 3.38 6.29 10.37
Investment Cost per year
Source: Ferguson, 2012; Young & Khennas, 2003
36
8.2 Data requirements for running the tool

Table 15 includes data requirements for running the Briquettes Component. A suggested data source is
provided.
Table 15: Data Requirements for Running the Tool
Data Definition and Sources

Biomass and its residue
The user selects the biomass/crops and its residue for detailed analysis.
Price of feedstock
If the price of feedstock is not available, then the user will need
information on hourly wages for skilled and unskilled workers (USD per
employee per hour) and fuel consumption of machinery typically used
in agricultural or forestry operations to calculate a proxy for this value.
Price of water
The user enters the current price of water (USD/m3).
Price of electricity
The user enters the current price of electricity (USD/kWh).
Price of diesel
The user enters the current price of diesel (USD/litre).
Feedstock storage cost
The user identifies the cost for storing the feedstock. The user can enter
(USD per tonne)
the current prices on storage for agricultural products in the country.
If this information is not available in the country, then the user can
estimate this based on the selection of the type of storage available in
the country. Then, he/she can use the estimated global cost for building
this type of storage, which is provided in the tool. Moreover, the size of
the storage site or container is estimated using the biomass storage
calculator.
Feedstock safety stock rate (%)
The user defines the values entered in each biomass storage calculator.
These values define the percentage of biomass that should be reserved
to operate the plant during shortage periods.
Briquette storage building cost
The user identifies the cost for storing the briquettes. The user can
(USD per tonne) enter the current prices on storage for agricultural products in the
country.
If this information is not available in the country, then the user can
estimate this based on the selection of the type of storage available in
the country. Then, he/she can use the estimated global cost for building
this type of storage, which is provided in the tool.
Safety stock ratio of briquette products The user determines the briquette stock rate to ensure sufficient supply
(%) of briquettes in the market.
Labour cost Unskilled and skilled workers in unit of USD per employee per hour.
Working hours of feedstock collection
Working hours of feedstock collection for manual and mechanized
methods.
The cost of transportation of feedstock
The user enters the cost of transportation in unit of USD per tonne per
(field/collecting point to plant) in unit of
km. The user can use the current methods of transportation to move
USD per tonne per km.
37
If transportation is done on foot or by bike, the user can include this

cost in the collection cost of feedstock. Alternatively, the user estimates
the cost by using the cost of labour per hour, working time, the amount
of material that can be transported and the approximate kilometres
that can be travelled under the selected method.
The transportation distance of feedstock It is determined based on the availability of biomass in a particular area
to briquette plant in kilometres by in relation to the amount required to operate each of the production
production capacity. capacity.
The cost of transportation of briquette
The user enters the cost of transportation in unit of USD per tonne per
products from plant to market in unit of
km. The user can use the current methods of transportation to move
USD per tonne per km.
If transportation is done on foot or by bike, the user can include this
cost in the collection cost of feedstock. Alternatively, the user estimates
the cost by using the cost of labour per hour, working time, the amount
of material that can be transported and the approximate kilometres
that can be travelled under the selected method.
The transportation distance of briquette
The user identifies an estimated transportation distance that will be
products to market in kilometres by
required to transport the briquette to market in kilometres according to
production capacity.
the briquette production capacity.
Transformation efficiency by different
It relates to the densification conversion process whereby biomass
types of feedstock 3
feedstock is converted from a low bulk density (80–100 kg/m ) to a high
3
bulk density (900 to 1300 kg/m ) briquette.
Operating parameters for briquette
Such as operating days per year, operating hours per day of manual and
system
mechanized briquette production.
Current market price of briquette Market price of briquette (USD/kg) in rural and urban areas.
Costing parameters Percentage of plant overhead cost, general and administrative cost and
maintenance cost.
Financial parameters o Inflation rate (%)
o Discount rate (%)
o Loan ratio (%)
o Loan interest rate (%)
o Loan term (years),
o Plant cost index http://base.intratec.us/home/ic-index
The types and quantities of typical fuels Fuels are charcoal, fuelwood, kerosene and LPG that used for heating
used for heating and cooking and cooking in urban and rural households (kg per day per household).
Price of fuels used for heating and The current price of fuels such as charcoal, fuelwood, kerosene and LPG
cooking in unit of USD/kg.
38
9 References
Bhattacharya, S C, & Kumar, S. (2005). Technology Packages : Screw-press briquetting machines and
briquette-fired stoves. Regional Energy Resources Information Center (RERIC).
Bhattacharya, S.C. (2002). RENEWABLE ENERGY TECHNOLOGIES IN ASIA, A Summary of Activities and
Achievements in Bangladesh. Regional Energy Resources Information Center (RERIC), Asian Institute of
Technology.
Dahlman, J., & Forst, C. (2001). Technologies Demonstrated at ECHO: Briquette presses for alternative fuel
use, (239).
EPA. (2007). Biomass Combined Heat and Power Catalog of Technologies. U. S. Environmental Protection
Agency, (September). Retrieved from www.epa.gov/chp/documents/biomass_chp_catalog.pdf
Ferguson, H. (2012). Briquette Businesses in Uganda The potential for briquette enterprises to address the
sustainability of the Ugandan biomass fuel market. GVEP International, (February).
Grover, P. D., & Mishra, S. K. (1996). Biomass Briquetting: Technology and Practices. Regional Wood Energy
Development Programme in Asia GCP/RAS/154/NET, (46).
Hite, L., & Smith, Z. (2011a). Single-Lever Large Biomass Briquette Press, 1–5.
Hite, L., & Smith, Z. (2011b). Single-Lever Square Biomass Briquette Press ENGLISH Inches, 1–3.
Hite, L., & Smith, Z. (2011c). Compound-Level Large Biomass Briquette Press, 1–4.
Hite, L., & Smith, Z. (2012). Biomass Briquette Mold Drawings and Assembly Compendium Round , Square ,
Stick , Cube & Chunk. Engineers Without Borders-USA, 1–31.
Lockard, J. (n.d.). How to make fuel briquettes without a press.
Poudel, M. S., Shrestha, K. R., & Singh, R. M. (2012). Screw Extruder Biomass Briquetting. Rentech
Symposium Compendium, 1(March), 27–31.
SNNPRs Investment Expansion Process. (2012). 77 . Profile on Production of Fuel Briquette. Retrieved from
http://www.southinvest.gov.et/Publications/SSNPR draft Profile/F/ Fuel Briquette.pdf
Tumuluru, J. S., Wright, C. T., Kenney, K. L., & Hess, J. R. (2010). A Technical Review on Biomass Processing :
Densification, Preprocessing, Modeling, and Optimization. 2010 ASABE Annual International Meeting.
Retrieved from www.inl.gov/technicalpublications/documents/4559449.pdf
Tumuluru, J. S., Wright, C. T., Kenny, K. L., & Hess, J. R. (2010). A Review on Biomass Densification
Technologies for Energy Application. Idaho National Laboratory, (August).
Young, P., & Khennas, S. (2003). Feasibility and Impact Assessment of a Proposed Project to Briquette
Municipal Solid Waste for Use as a Cooking Fuel in Rwanda. Consultancy Report to the Business Linkages
Challenge Fund (BLCF), (January).
39

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BIOENERGY AND FOOD SECURITY

RAPID APPRAISAL (BEFS RA)

Energy End Use Options Module

Intermediate or Final Products Sub-Module

I. Introduction to the Approach and the Manuals

II. Country Status Module

III. Natural Resources Module

Section 1: Crop Production Tool

Section 2: Crop Budget Tool

Crop Residues and Livestock Residues

3. Woodfuel and Wood Residues

Section 1: Forest Harvesting and Wood Processing Residues

Section 2: Woodfuel Plantation Budget

IV. Energy End Use Options Module

1. Intermediate or Final Products

2. Heating and Cooking

4. Heat and Power

Section 1: CHP (cogeneration)

Section 2: Biogas Industrial

Ethanol and Biodiesel

1 Overview of the Energy End Use Option (End Use) Module

Figure 1: The Structure of the Energy End Use Option Module

2 The Briquette Component

Figure 3: Layout of the Briquettes Results Sheets

3 Terms and Definitions in the Briquettes Component

4 Scope and Objective of the Briquettes Component

5 Running the Briquette Component

5.1 Step 1: Energy demand

To run this analysis, the user has to enter data on:

- Market price of each energy type in rural households (Figure 6, label 1)

Figure 6: Energy Demand in Rural and Urban Areas

5.2 Step 2: Defining the feedstock

The user will:

Figure 7: Feedstock Selection

Step 2.B Feedstock price (USD/t)

The user will get a “warning” before continuing

- Forestry and plantation residues

3. Enter the labour requirements (person-hour per

Table 1: Specific Feedstock that can be Used in the Briquette System

Figure 9: Chemical Binder and Feedstock Storage Cost

Step 2.C Chemical Binder Guidance: According to literature,

Step 2.D: Feedstock storage cost (USD/t)

Estimated Cost of Storage Unit Min Average Max

Figure 10: Feedstock Storage Calculator

For this example, Feedstock 1 “Cassava Stalk” is harvested in March and

5.3 Step 3: Production cost and financial parameters

Figure 11: General Inputs

1. Utilities cost: the price of water (USD/m3) and electricity (USD/kWh).

6. Transportation cost of briquettes (USD/t/km): cost of

5.4 Step 4 (Optional): Calculation of the production

Figure 12: Production Cost Calculation

Figure 13: Processing Costs of Briquettes

2. The transportation distance of feedstock to

6 Assumptions and Limitations of the Briquettes Component

The limitations of the Briquettes Component are:

1. Manual briquette production is set at 4 kg per hour.

7 The Results of the Briquettes Component

7.1 Overview of the production cost calculations (optional)