INTRODUCTION

Burning of maize cobs have been a vital source of energy in industries for decades.
This burning of maize cobs are prelevant due to the rising cost of petroleum products.
However, conventional burning of maize cobs suffers from inefficiency from irregular
shape of maize cobs and lightweight making them difficult to compact and load. This
project proposal aims to address these issues by designing and developing a portable
machine that reduces the size of maize cobs and load the cut cobs onto a truck.

Chapter 1: Introduction

Background of the Study:

The global shift towards clean and sustainable energy sources in response to rising
petroleum costs has prompted industries, particularly in Kenya, to explore alternative
energy options. In Kenya, maize cobs have gained attention as a renewable biomass
energy source for fueling boilers. Maize cobs are abundant agricultural waste, but their
lightweight and irregular shape present challenges in terms of compaction and loading.
This study aims to design portable machines that can effectively process maize cobs for
use as a clean energy source.

Problem Statement:
The lightweight and irregular shape of maize cobs make them impractical for direct use
as fuel in boilers. To harness their potential as a clean energy source, there is a need to
design portable machines that can efficiently reduce the size of the cobs to a uniform
length of 5 cm and load them onto trucks with a maximum height of 4.7 meters.
Additionally, achieving a minimum processing capacity of 5 tonnes per hour is essential
to make the use of maize cobs for biomass energy economically viable.

Justification:
The design of these machines is crucial for several reasons:

Utilizing maize cobs as a biomass energy source can significantly reduce the
dependence on fossil fuels, leading to reduced environmental impact and economic
benefits.
Addressing the challenge of processing maize cobs efficiently will enable industries to
tap into a readily available and sustainable energy resource.
By reducing waste in maize farming, these machines contribute to a cleaner
environment and more sustainable agricultural practices.
Scope of the Study:
The scope of this study encompasses the design and development of two portable
machines: one for maize cob size reduction and another for loading processed cobs
onto trucks. The study will also consider the efficiency and capacity of the machines to
ensure they meet the minimum requirement of processing 5 tonnes of maize cobs per
hour.

Objectives:
The main objectives of this study are as follows:

To design a portable machine capable of reducing maize cobs to a uniform length of 5

cm.
To design a portable machine for loading processed maize cobs onto trucks with a
maximum height of 4.7 meters.
To achieve a minimum processing capacity of 5 tonnes of maize cobs per hour.
Specific objectives include:
Specific Objectives:

Design Maize Cob Size Reduction Machine:

Develop a portable machine capable of reducing maize cobs to a uniform size of 5 cm.
Ensure that the machine is efficient, cost-effective, and easy to operate, taking into
account local conditions and operator skills.
Design Maize Cob Loading Machine:

Design a portable machine for loading processed maize cobs onto trucks with a
maximum height of 4.7 meters.
Ensure the loading machine is safe, easy to maneuver, and compatible with various
truck bed sizes and types.
Achieve Minimum Processing Capacity:
Ensure that both the size reduction machine and the loading machine can collectively
process a minimum capacity of 5 tonnes of maize cobs per hour.
Optimize the machines' performance to meet or exceed this target, while also
considering energy efficiency and maintenance requirements.
Consider Safety and Environmental Impact:

Incorporate safety features into both machines, including emergency stop mechanisms
and guards to protect operators.
Minimize any adverse environmental impact during the processing of maize cobs, taking
into account emissions and waste disposal.
Local Adaptability and Affordability:

Ensure that the machines are suitable for use in Kenyan industrial and agricultural
settings, considering local infrastructure and resources.
Keep the cost of manufacturing and operating the machines reasonable, making them
accessible to a wide range of users.
Reliability and Durability:

Design the machines with robust and durable components to ensure a long operational
lifespan, minimizing downtime and maintenance costs.
Ease of Transport and Mobility:

Consider the portability and mobility of the machines to enable easy relocation within or
between processing facilities.
Ensure that the machines can be transported to remote locations where maize cobs are
generated.
Optimal Energy Efficiency:

Design the machines with an emphasis on energy efficiency to minimize energy

consumption while maintaining high processing rates.
Explore the potential for using renewable energy sources, such as solar or wind power,
in the machine's operation.
Operator Training and User-Friendly Design:
Develop user manuals and provide training to operators to ensure they can use the
machines effectively and safely.
Ensure that the design and interface of the machines are user-friendly, making them
accessible to operators with varying levels of expertise.
performance Testing and Quality Assurance:

Conduct rigorous performance testing and quality assurance checks on the machines to
validate that they meet the specified objectives.
Fine-tune the machines based on feedback and actual performance in real-world
settings.
These specific objectives will guide the design and development of the portable
machines, ensuring they meet the needs of industries in Kenya aiming to utilize maize
cobs as a clean and sustainable source of biomass energy.

Evaluating the morphological structure of the maize cob.

Analyzing the impact of using agricultural waste as an energy source on the
environment.
Assessing existing technologies and methods for processing maize cobs.
Activities Performed During the Project Design:

Literature review on the maize plant, maize seed, and maize waste.
Research on agricultural waste and its environmental implications.
Study of the morphological structure of maize cobs.
Evaluation of existing technologies for processing agricultural waste.
Design and development of the maize cob size reduction machine.
Design and development of the maize cob loading machine.
Chapter 2: Literature Review

Description of the Maize Plant:

Maize (Zea mays) is a cereal crop widely cultivated in Kenya. It is known for its tall
stalks, large leaves, and the production of cobs containing maize seeds.

Maize Seed and Maize Wastes:

Maize seeds are the edible part of the maize plant, while maize wastes, including cobs,
husks, and stalks, are byproducts of maize cultivation.

Agricultural Waste and the Environment:

The improper disposal of agricultural waste, including maize cobs, can lead to
environmental issues such as pollution, habitat degradation, and increased greenhouse
gas emissions.

The Maize Cob Morphological Structure:

Maize cobs consist of a central axis (cob) surrounded by kernels, with the husk and
tassel at Existing Research about the Use of Maize Cobs as Feeds:

Research into the utilization of maize cobs as a source of biomass energy and
feedstock for various applications has gained momentum globally, including in Kenya.
Several studies have highlighted the advantages and challenges associated with maize
cob usage:

Biomass Energy Source: Various research papers emphasize the feasibility of maize
cobs as a renewable and sustainable biomass energy source. Maize cobs have been
used successfully to fuel boilers, reducing dependence on fossil fuels and mitigating
greenhouse gas emissions.

Energy Conversion Technologies: Research has explored different technologies for

converting maize cobs into energy. This includes direct combustion, gasification, and
pyrolysis. Each method has its advantages and limitations in terms of energy efficiency
and environmental impact.
Combustion Characteristics: Studies have investigated the combustion characteristics
of maize cobs, such as calorific value, ash content, and emissions. Understanding these
properties is crucial for optimizing boiler performance and reducing environmental
impact.

Other Uses of Maize Cobs:

In addition to their role in biomass energy production, maize cobs have various other
applications:

Animal Feed: Maize cobs can be used as animal feed, primarily for ruminants like cattle
and goats. Their fibrous nature provides roughage, and they are a valuable source of
nutrients.

Soil Amendment: Ground maize cobs can improve soil structure, moisture retention,
and nutrient content when used as a soil amendment in agriculture.

Crafts and Artwork: In some regions, maize cobs are used in crafts and artwork,
highlighting their versatility in creative and cultural endeavors.

Cob Processing and Usage Practices:

In Kenya and similar regions, the use of maize cobs has been characterized by certain
practices:

Manual Cob Reduction: Historically, maize cobs have been reduced in size manually,
often through chopping or breaking, which is a labor-intensive and time-consuming
process.

Transportation Challenges: The irregular shape and lightweight nature of maize cobs
have posed challenges in transportation. This has prompted the need for efficient
compaction and loading solutions.
Energy Access: As an energy source, maize cobs have been accessible to rural areas
where access to conventional energy sources is limited. Their use as a local energy
resource can significantly benefit communities.

Environmental Awareness: There is growing awareness of

the top.

By addressing the challenges associated with processing maize cobs, this study aims to
contribute to the sustainable utilization of agricultural waste for clean energy production.

Existing Maize Cob Milling Technology:

In the context of utilizing maize cobs as a clean energy source, several existing milling
and processing technologies have been applied. Understanding these technologies is
essential when designing the proposed portable machines for maize cob size reduction
and loading. Here are some examples of existing maize cob milling technology:

Hammer Mills:
Hammer mills are commonly used in maize cob processing. They consist of rotating
hammers that impact the maize cobs, breaking them into smaller pieces.
These machines are versatile and can handle a variety of materials. However, the
output size may not always be uniform.
Grinders and Crushers
Maize cobs can also be processed using grinders and crushers, which crush the cobs
into smaller particles.
These machines can achieve a relatively uniform size, but they may have limitations in
terms of throughput and energy efficiency.
Combustion Technology
In the context of biomass energy, maize cobs are often used in combustion technology.
This involves direct burning of maize cobs to produce heat for boilers.
Specialized combustion chambers and grates are designed to accommodate maize
cobs, but their efficiency can be impacted by cob size and moisture content.
Pelletizing Machines:
Some industries use pelletizing machines to process maize cobs into uniform-sized
pellets. These pellets can then be used as a more convenient and efficient fuel source.
Pelletizing machines are effective in producing consistent cob size and can enhance
combustion efficiency.
Chaff Cutters:

Chaff cutters are simple machines used for cutting and shredding agricultural residues,
including maize cobs.
They are often manually operated and are more commonly used in small-scale
operations.
Custom-Built Machinery:

Some industries and research institutions have developed custom-built machinery

specifically designed for maize cob processing. These machines are engineered to
address the challenges associated with cob size and shape.
While existing technology serves as a foundation for maize cob processing, there are
certain limitations and challenges, particularly in terms of portability, uniformity,
throughput, and adaptability to various settings. The proposed portable machines aim to
address these limitations and provide a comprehensive solution for reducing maize
cobs to a uniform size of 5 cm and efficiently loading them onto trucks with a maximum
bed height of 4.7 meters. Additionally, achieving a minimum capacity of 5 tonnes per
hour is a critical objective, ensuring that the machines meet the requirements of
industrial-scale operations in Kenya and beyond.

Background of the Machine Components in Relation to Maize Cob Milling:

To design a portable machine that can efficiently reduce maize cobs to 5 cm and
another machine to load them onto trucks with a maximum height of 4.7 meters, it's
important to understand the key components involved in such equipment. These
components play crucial roles in achieving the desired outcomes:

Feeding Mechanism: The feeding mechanism is responsible for introducing maize cobs
into the machine for processing. It must be designed to handle cobs of varying sizes
and ensure a continuous and controlled feed to maximize processing efficiency.
Cob Size Reduction Mechanism: This component, often involving blades, hammers, or
crushers, is responsible for reducing the size of maize cobs to the specified 5 cm length.
It needs to be designed for durability, precision, and ease of maintenance.

Conveying System: A conveying system is essential for transporting processed maize

cobs to the loading machine. This system can use conveyors, augers, or other
mechanisms to ensure a smooth transition between the two machines.

Loading Mechanism: The loading machine component plays a crucial role in efficiently
transferring processed maize cobs onto trucks. It typically involves a conveyor or other
materials-handling system designed to reach the required truck height of 4.7 meters.

Control System: A control system is necessary to manage and coordinate the operation
of the machines. It includes interfaces, sensors, and control units that enable operators
to adjust settings, monitor performance, and ensure safety.

Power Source: Depending on local conditions and availability, the machines can be
powered by electric motors, gasoline engines, or other energy sources. The choice of
power source affects mobility and operational costs.

Mechanical Properties of Maize Cobs:

Understanding the mechanical properties of maize cobs is essential for designing

effective machines. These properties impact the selection of materials, the configuration
of machine components, and the overall efficiency of the process. Some relevant
mechanical properties of maize cobs include:

Density: Maize cobs have a relatively low density due to their lightweight nature. This
affects how they are handled and compacted, as well as the energy required for size
reduction.

Moisture Content: Moisture content can vary, impacting the ease of processing and
combustion efficiency. High moisture levels can affect the combustion process, while
overly dry cobs may be brittle and challenging to handle.
Strength and Hardness: The strength and hardness of maize cobs influence the design
of size reduction mechanisms. Hard cobs may require more robust cutting or crushing
components.

Size and Shape Variability: The irregular shape and varying sizes of maize cobs pose a
challenge for consistent processing. The design of the feeding mechanism and size
reduction components must account for this variability.

Abrasion and Wear: Maize cobs can be abrasive, which may result in wear and tear on
machine components. Material selection and component durability are essential to
minimize maintenance and replacement costs.

Friction and Flow Properties: Maize cobs have specific friction and flow properties that
affect their movement through the machine components. Understanding these
properties helps in the design of conveyors and loading systems.
By considering the machine components and the mechanical properties of maize cobs,
the design of the portable machines can be optimized to efficiently process maize cobs
for use as biomass fuel. This knowledge informs material selection, component design,
and the overall functionality of the machines to meet the specified objectives.
Crushing Speeds for Maize Cobs and Particle Size Reduction Methods:
To design a portable machine that reduces maize cobs to a size of 5 cm while achieving
a minimum capacity of 5 tonnes per hour, it's essential to consider crushing speeds and
particle size reduction methods. The choice of the appropriate method and operating
speeds is crucial for optimizing the efficiency of the maize cob processing system. Here
are some considerations:
1. Maize Cob Crushing Speed:
The crushing speed, often expressed in terms of rotations per minute (RPM) or linear
speed, determines the rate at which maize cobs are processed. A balance must be
struck to ensure high throughput while maintaining effective size reduction.
2. Particle Size Reduction Methods:
Various methods can be employed to reduce maize cobs to the desired size. The
choice of method can significantly impact efficiency and the quality of the processed
material. Some common methods include:
a. Hammer Milling: Hammer mills are commonly used for size reduction. They employ
high-speed rotating hammers to impact and break maize cobs. The speed at which the
hammers rotate and the size of the perforations in the screen can control particle size.
b. Crushers and Grinders: Crushers and grinders use compression, impact, or shearing
forces to crush maize cobs into smaller particles. The choice of the type of crushers and
grinders and their settings can influence the final size.

METHODOLOGY.

Designing a portable system for reducing maize cobs to 5 cm in size and loading them
onto trucks with a maximum height of 4.7 meters, while maintaining a minimum capacity
of 5 tonnes per hour, involves a structured methodology. The methodology includes a
combination of desk study, design parameters, and general design considerations.
Here's a step-by-step approach:

1. Desk Study:

Literature Review: Conduct an extensive review of existing research, studies, and

technologies related to maize cob processing, size reduction, and materials handling.
Explore best practices, lessons learned, and innovative solutions used in similar
applications.
Market Research: Investigate the availability of materials, components, and
technologies in the local and global markets. Identify potential suppliers and evaluate
their suitability for the project.
Regulatory Compliance: Research and understand local and international regulations
and standards governing the design, manufacturing, and operation of the machines,
especially safety and environmental regulations.

2. Design Parameters:
Capacity:
Determine the required processing capacity, which is a minimum of 5 tonnes per hour.
This will be a fundamental design parameter for both machines.
Maize Cob Characteristics:
Analyze the physical properties of maize cobs, including their size, shape, moisture
content, and mechanical properties. These characteristics will guide the design of the
size reduction and loading machines.
Uniformity of Output:
Specify the desired output size, ensuring it is consistently reduced to 5 cm.
Energy Efficiency:
Define energy efficiency targets to ensure the machines operate as sustainably as
possible.

3. General Design Considerations:

 Machine Portability:
Ensure that both the size reduction and loading machines are portable and can be
easily moved to different locations for maize cob processing.
 Material Selection:
Select appropriate materials for the machine components based on factors such as
strength, durability, and cost-effectiveness. Consider the wear and tear that may result
from processing maize cobs.
 Safety Features:
Integrate safety mechanisms, including emergency stops, safety guards, and operator
training procedures, to protect workers and ensure safe operation.
 Environmental Impact:
Minimize the environmental impact by considering emissions, waste management, and
sustainable design practices.
 Power Source:
Choose an appropriate power source, whether it be electric, gasoline, or other
renewable options, based on local availability and mobility requirements.

 Operator-Friendly Design:
Ensure the design is user-friendly, taking into account the skills and expertise of the
operators who will be using the machines.

 Optimization of Size Reduction:

Select the most suitable size reduction method (e.g., hammer milling, crushing, cutting)
and design the machine components accordingly.

 Efficient Loading Mechanism:

Design the loading machine to efficiently transfer processed maize cobs to trucks,
considering reach, height, and adaptability to different truck types.
  Real-time Monitoring:
Incorporate monitoring and control systems to manage and adjust machine
performance in real-time, ensuring consistent output quality.

4. Prototyping and Testing.

Develop prototypes of the size reduction and loading machines based on the design
parameters and considerations.

Conduct rigorous testing to evaluate the efficiency, safety, and environmental impact of
the machines.

Fine-tune the designs based on test results and feedback, ensuring they meet the
specified objectives.

5. Scaling and Production.

Once the prototype testing is successful, scale up production for commercial use,
considering local manufacturing capabilities and costs.
6. Operator Training and Maintenance Procedures.
Develop training programs for operators to ensure they can effectively and safely
operate the machines.

Establish maintenance procedures to keep the machines in optimal working condition.

By following this methodology, you can systematically design and develop the portable
machines needed to process maize cobs for biomass energy production in Kenya,
effectively addressing the challenges posed by their lightweight and irregular shape.

Designing a portable system for processing maize cobs into 5 cm pieces and loading
them onto a truck with a maximum height of 4.7 meters while maintaining a minimum
capacity of 5 tonnes per hour involves two separate machines:
 1. Maize Cob Cutting Machine:
Conceptual Design Considerations:
The machine should be portable, easy to transport to various locations.
It should be efficient, capable of processing a large volume of maize cobs quickly.
Safety features are essential to prevent accidents during operation.
The design should be relatively simple for ease of operation and maintenance.
The machine should be able to cut maize cobs into uniform 5 cm pieces.

Machine Description:
The maize cob cutting machine consists of a conveyor belt or feeding mechanism for
transporting maize cobs to the cutting section.
The cutting section includes a rotating drum or blade system with adjustable settings to
ensure that the cobs are cut into 5 cm pieces.
A power source such as a diesel or electric engine provides the necessary energy for
the cutting operation.
Safety features such as emergency stop buttons and safety guards are integrated into
the design.
The machine can be mounted on a trailer for easy mobility between locations.
Output conveyors may be used to transport the cut maize cobs to the loading machine
or directly to storage containers.

2. Maize Cob Loading Machine:

Conceptual Design Considerations:

Portability is crucial for transportation to various sites.

The loading machine should have a high loading capacity to meet the minimum
requirement of 5 tonnes per hour.
Safety features are necessary to prevent accidents during the loading process.
The design should be efficient and capable of handling irregularly shaped maize cobs
effectively.
It should be able to load the cobs onto a truck with a maximum height of 4.7 meters.
Machine Description:

The maize cob loading machine consists of a hopper or receiving area for the cut cobs
from the cutting machine.
An elevating mechanism, such as a conveyor belt or a bucket elevator, is used to lift the
cobs to the required height.
The loading machine should have a flexible arm or conveyor that can reach the height
of the truck's top edge (4.7 meters) and deposit the cobs into the truck bed.
A power source, similar to the cutting machine, is used to operate the loading
mechanism.
Safety features include sensors to detect the truck's height and prevent overloading, as
well as emergency stop mechanisms.
Like the cutting machine, it can be mounted on a trailer for easy mobility.
Both machines should be designed with durability and ease of maintenance in mind to
ensure their longevity and minimize downtime. Regular maintenance schedules and
user training should be provided to ensure safe and efficient operation. It is also crucial
to consider environmental regulations and emissions controls when choosing a power
source for these machines.
1. Maize Cob Cutting Machine:
Conceptual Design Considerations:

 Portability:
The machine should be designed for easy transport between different locations.
 Efficiency:
It must be capable of processing a significant volume of maize cobs quickly to meet the
5-tonne per hour requirement.
 Safety:
Incorporate safety features to prevent accidents during operation.
 Uniform Cutting:
The design should ensure that maize cobs are consistently cut into 5 cm pieces.
 Simplicity:
Keep the design relatively simple for ease of operation and maintenance.
  Power Source:
Choose a suitable power source, such as an electric motor or a diesel engine.
 Operation:
Maize cobs are loaded onto a conveyor belt or feeding mechanism.
The cobs are transported to the cutting section, where a rotating drum or blade system
is in place.
The operator sets the machine to cut the cobs into 5 cm pieces.
The power source provides the necessary energy for the cutting operation.
Safety features, including emergency stop buttons and safety guards, ensure safe
operation.
The cut maize cobs can be conveyed to the loading machine or storage containers
through output conveyors.
2. Maize Cob Loading Machine:

Conceptual Design Considerations:

 Portability:
Like the cutting machine, the loading machine should be easy to transport.
High Capacity: It must have a high loading capacity to meet the 5-tonne per hour
requirement.
 Safety:
Include safety features to prevent accidents during the loading process.
 Adaptability:
The design should be efficient and capable of handling irregularly shaped maize cobs
effectively.
 Reach:
Ensure that it can load cobs into a truck with a maximum height of 4.7 meters.
 Power Source:
Similar to the cutting machine, select an appropriate power source for operation.
Operation:
The Maize Cob Loading Machine receives the cut maize cobs from the cutting
machine's output conveyors.
An elevating mechanism, such as a conveyor belt or bucket elevator, lifts the cobs to
the required height.
The loading machine is equipped with a flexible arm or conveyor that can reach the
height of the truck's top edge (4.7 meters) and deposit the cobs into the truck bed.
The operator uses the power source to control the loading mechanism.
Safety features, including sensors to detect the truck's height and prevent overloading,
as well as emergency stop mechanisms, ensure safe operation.
As with the cutting machine, the loading machine can be mounted on a trailer for easy
mobility.
Regular maintenance schedules and user training are crucial to ensure the safe and
efficient operation of both machines. Environmental considerations should also be taken
into account when choosing the power sources for these machines, as they contribute
to biomass energy's sustainability and cleanliness.

Designing a portable system for processing maize cobs into 5 cm pieces and loading
them onto a truck with a maximum height of 4.7 meters while maintaining a minimum
capacity of 5 tonnes per hour involves two separate machines: a Maize Cob Cutting
Machine and a Maize Cob Loading Machine. Below are the conceptual design
considerations and an estimation of the capacity of each machine:

1. Maize Cob Cutting Machine:

Conceptual Design Considerations:

Portability: The machine should be designed for easy transport between different
locations.
Efficiency: It must be capable of processing a significant volume of maize cobs quickly
to meet the 5-tonne per hour requirement.
Safety: Incorporate safety features to prevent accidents during operation.
Uniform Cutting: The design should ensure that maize cobs are consistently cut into 5
cm pieces.
Simplicity: Keep the design relatively simple for ease of operation and maintenance.
Power Source: Choose a suitable power source, such as an electric motor or a diesel
engine.
Estimation of Capacity:
The capacity of the Maize Cob Cutting Machine can be estimated based on the
following factors:

Cutting Mechanism: The rate at which the cutting mechanism can process maize cobs
(e.g., rotations per minute for a blade or drum system).
Feeding Rate: The rate at which maize cobs are fed into the machine (e.g., conveyed
by a conveyor belt).
Dwell Time: The time it takes for a maize cob to be processed and cut into 5 cm pieces.
Machine Downtime: Time for maintenance, cleaning, and any potential interruptions.
To estimate the capacity, you need to determine the product of these factors:

Capacity (in tonnes per hour) = (Cutting Mechanism Rate * Feeding Rate * Dwell
Time) / 60

For example, if the cutting mechanism can process 500 cobs per minute, the feeding
rate is 1 cob per second, and the dwell time is 1 second per cob, the estimated capacity
would be:

Capacity = (500 cobs/minute * 1 cob/second * 1 second/cob) / 60 minutes/hour = 8.33

tonnes per hour

This calculation will provide an estimate of the machine's capacity, which should ideally
meet or exceed the 5-tonnes per hour requirement.

2. Maize Cob Loading Machine:

Conceptual Design Considerations:

Portability: Like the cutting machine, the loading machine should be easy to transport.
High Capacity: It must have a high loading capacity to meet the 5-tonne per hour
requirement.
Safety: Include safety features to prevent accidents during the loading process.
Adaptability: The design should be efficient and capable of handling irregularly shaped
maize cobs effectively.
Reach: Ensure that it can load cobs into a truck with a maximum height of 4.7 meters.
Power Source: Similar to the cutting machine, select an appropriate power source for
operation.
The estimation of capacity for the Maize Cob Loading Machine is similar to that of the
cutting machine, taking into account factors such as the loading mechanism's rate,
feeding rate, and downtime.

These estimations help ensure that both machines meet or exceed the required
capacity of 5 tonnes per hour, making the system effective in processing maize cobs for
biomass fuel.

Designing portable machines to process maize cobs for use in biomass energy
production involves two key components: a size reduction machine and a loading
machine. Let's break down the design of each machine and determine the power
requirements for them.

Maize Cob Size Reduction Machine:

Objective: Reduce maize cobs to a size of 5 cm for easy handling and transport.

Design Elements:

Cutting Mechanism: You can use a rotor with sharp blades to cut the maize cobs. This
rotor should be powered by an electric motor.
Feeding System: A conveyor belt or a hopper that continuously feeds the maize cobs to
the cutting mechanism.

Power Source: An electric motor will be the power source for the cutting mechanism.

Size Reduction Rate: To achieve a minimum capacity of 5 tonnes per hour, you need to
calculate the rate at which maize cobs are fed and the size reduction efficiency.

Power Requirement Calculation:

To determine the power required by the cutting machine, you need to calculate the work
required to cut the maize cobs. This work depends on the force needed to cut and the
speed at which the cutting occurs. The power (P) required can be calculated using the
following formula:

P= W/t
Where:

P is the power in watts (W).

W is the work required in joules (J).
t is the time in seconds (s).
To calculate W, you need to determine the force (F) required to cut the maize cobs and
the distance (d) over which the force acts. The force can be calculated using the
formula:
F=(m.a)/ η

Where:

F is the force in newtons (N).

m is the mass of the maize cobs being cut (in kg).
a is the acceleration (in m/s^2).
η is the mechanical efficiency of the cutting mechanism.
Once you have F, you can calculate the work (W) as:
W=F.d

With the work calculated, you can determine the power required by the cutting machine.

Maize Cob Loading Machine:

Objective: Load the cut maize cobs onto a truck with a maximum height of 4.7m.

Design Elements:

Conveyor or Elevator System: A mechanism that lifts and loads the cut maize cobs onto
the truck. This could be a conveyor belt or an elevator system.

Power Source: An electric motor will power the conveyor or elevator system.

Power Requirement Calculation:

The power required for the loading machine will depend on the weight of the cobs being
lifted, the height they need to be lifted, and the speed at which they are loaded onto the
truck. Use the following formula to calculate the power:

P=(W.h)/t

Where:

P is the power in watts (W).

W is the weight in kilograms (kg).
h is the height in meters (m).
t is the time in seconds (s).
To achieve a minimum capacity of 5 tonnes per hour, you need to ensure that the
loading machine can handle this amount of material within the specified time frame.