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SCIENTIFIC AND TECHNICAL REPORT IN EXTENSO
(STR)
TOPIC: Promotion in Romania of energetic willow cultivation technology (SALIX
VIMINALIS) as an alternative source of clean energy (TCSE)
STAGE 3: / Achievement experimental models
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2013
Summary of the stage
The stage “Achievement experimental models” consists in the achievement of the following
technical equipment: “Technical equipment for energetic willow planting” and „Technical Equipment
for Cutting and Shredding Energetic Willow” which is based on the execution documentation
elaborated at the stage II.
As objectives the project proposes:
Compliance with the European Framework Programme regarding the research in the energetic
field in order to support the energy policy objectives. They aim to improve the acceptability level,
competitiveness and the possibilities of traditional energies use (eg reactor safety and radioactive waste
management, coal gasification and liquefaction), encouraging the adoption of new forms of energy
(alternative energies, new technologies for supplying with sustainable energy , the nuclear fusion ) or
achieving of energy savings and the promotion of a rational use.
The Seventh Framework Programme of the European Community regarding research, the
technological development and the demonstration activities covers the period 2007-2013 [COM (2005)
119] and sets targets for research to ensure the reduction of energy consumption. It also proposes a
cooperation and an increased focus on research in this area, including proposals on funding of these
actions.
Respecting this framework program ensures stimulation of growth of private investments in R &
D, in their activities in collaboration with research institutes in order to facilitate the completion and
transfer of results to market.
The establishment of an energetic willow plantation being done only once (the service life being of
25-30 years), put into service unused lands, it avoids (or it greatly reduces) the forest deforestations
caused by the growing need for cheap fuel, favors the stimulation of partnerships (research
organizations, NGOs, economic agents, universities) to shorten the road from the scientific knowledge
to technology with socio-economic impact in alignment with the needs and market development.
The main use of biomass will be given for heating of buildings (dwellings, schools, dispensaries,
kindergartens etc.) from communes, which will consume approx. 80% of the total production, where
20% of the biomass can be used for the production of biofuels (12%) and electricity (8%).
All these estimations belong to the Ministry of Economy and NL Agency (Netherlands), the
creation of new jobs for unqualified people. Harvesting is done during the vegetal break, after leaf fall
(serve as fertilizer) so in the months from November to March, a period when agricultural equipment are
not used for other annual works. Thus occurs the taking over yearly of 20-30 t / ha of sludge (as natural
fertilizer) derived from wastewater treatment.
This property, in addition to the advantage that in an area where the plantation can be flooded with
residues from the treatment stations, it grows faster, the waste waters must not be biologically treated
(expensive operation) and on the other hand the resulting waters from the treatment stations reach into
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very clean rivers, avoiding pollution but also additional costs due to penalty payments for the inadequate
quality of discharged waters.
Scientific and technical description
Within the stage was achieved the Experimental Model of the two equipments: Technical
equipment for planting energetic willow, EIS and Technical equipment for cutting and chopping
energetic willow, ETSE.
1. Technical equipment for planting energetic willow
The experimental model of the technical equipment EIS is intended for the mechanization
technologies of energetic willow crops establishment, being provided for this purpose with mechanically
driven planting elements.
Fig.1 Technical Equipment for Energetic Willow Crop Establishment, EIS
(View from profile)
1.1 Field of use
Field of use of technical equipment of energetic willow establishment contains technologies and
products designed to solve and implement solutions to complex socio-economic problems of national
priority and international current affairs, namely: replacement of fossil energetic sources (coal, oil, etc.)
with alternative sources (burning of energetic crops), which have a very fast growth rate (about 3cm /
day in summer), with a high energetic power (4900Kcal / Kg), burning with near zero emissions and
very low production costs (planting one hectare of land costing about 1700 euros - source:
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www.salcieenergetica.ro), in order to achieve the proposed target of Romania that up to 2020 approx.
65% of the total renewable energy consumed will come from biomass.
The plants that are best suited for this purpose are: the energetic willow, miscanthus, artichoke
and poplar.
It is technical equipment type carried in transportation and during the working and is designed to
operate aggregated with wheeled agricultural and forestry tractors with powers ranging from 80 to 150 hp.
1.2 Structure
The experimental model establishment of technical equipment for the energetic willow EIS (Fig.
1) consists of the following subassemblies: frame, frame section planting, planting mechanism, driving
system, skate left, skate right, coulter assembled, back support, bench seat , double-acting cylinder,
marker, cuttings boxe etc.
Fig. 2. Technical Equipment for Energetic Willow Crop Establishment, EIS EIS (Rear view)
The framework (fig. 3) is a welded construction, in pipe of square section, on which are in the
front side are provided the three points of attachment to the three-point suspension mechanism of the
tractor.
The framework of planting section (fig. 4) is a welded construction having at the anterior side
a plate for the attachment on the coupling framework and at the rear side fixing elements for the
mechanism of planting cuttings the and of the driving and and compaction system.
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Fig. 3. Framework Fig.4 Framework of planting section
The planting mechanism (fig. 5) is of the disc type with arms and clamping tweezers of the cuttings.
Fig. 5. Planting mechanism Fig. 6. Driving system
The driving system (fig. 6) is provided with articulated fasteners and a gear mechanism for
transmitting the movement from the driving and compaction wheel to the planting mechanism.
1.3 Dimensional and constructive technical characteristics
- Type carried
- Energetic source 80 ... 150 hp tractor
- Number of coulters 2
- Length of cuttings, mm 180…250
- Diameter of cuttings, mm 5…25
- Planting is done in two rows at distances of, cm 75
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- The free space between two rows planted, cm 150
- The distance between two cuttings (along the line), cm 50…100
- The overall dimensions, mm
- length 2550
- width 2000
- height (with the row markers raised) 1420
- Weight, daN 1150
1.4 Operating mode
The working process of the technical equipment involves the completion of three operations,
namely:
- ditch opening by the coulter;
- planting of energetic willow cutting done by the planting mechanism;
- soil compaction by the wheels of driving and compaction mechanism.
The ditch opening involves the cutting of soil in the vertical plane on a depth "a" and a width "b",
the deformation and movement of the cutted soil in the horizontal plane, in order to achieve the ditch.
Planting is carried out by the planting mechanism into two rows at distances of 75 cm between them,
followed by a free space of 150 cm, and then again two rows with 75 cm distance between them (fig. 7).
Fig. 7 - The planting scheme of energetic willow
For achieving a planting operation at high indexes of quality, the land must have a proper
processing condition, characterized mainly by the depth and degree of grinding.
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1.5. Conditions of achievement
The EM of this equipment was conducted by specialized personnel from INMA. According to
the staff list, was appointed the working group.
In the beginning was analyzed the execution project concerning the composition, functional and
kinematic scheme, were identified the main raw materials and materials required, was prepared the
technological documentation of execution was prepared the technological documentation for
constraction (technological sheets, consumption of materials), was drawn up the mounting technology
documentation, have been identified the potential suppliers for the raw materials and materials and then
was carried the supplying with raw materials and materials.
The raw materials and materials supplied for the execution of the experimental model were
received based on the documents accompanying the consignment. Certificates of quality relative tom the
raw materials and materials entered into the storehouse were highlighted in a register of entries existing
at the shopkeeper of the storehouse. No non-conforming raw materials and materials were supplied.
The subassemblies from collaborations were received by the head of The Executive Department
based on the quality certificate which was properly completed by the supplier. The subassemblies
quality certificates are kept by the head of The Executive Department.
Were supplied and used from the mass production the following: bearings, cables and removable
fasteners such as: screws, nuts, flat washers, spring washers, etc..
During the course of execution activity of the technical equipment, where appropriate, was taken
into account the standards and regulations.
The consultancy and technical assistance to the execution of parts and of sub-assemblies of the
experimental model was given by specialists from INMA Bucharest - RDI DEPARTMENT: Research,
Development and Innovation.
The parts and sub-assemblies of the experimental model were made in the execution workshops
of INMA Bucharest - The EXECUTIVE DEPARTMENT.
Execution of some parts in sheet metal was made using CNC machines (CNC cutting center type
HST-C 6/2500, processing center by stamping ALPHA- CADMAN 1012TK, Center for bending of
metal sheets type PPEB-4 C) and devices (TDC for machining by splintering and welding devices)
which enabled the shortening of time and increasing the execution accuracy.
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2. Technical Equipment for Cutting and Shredding Energetic Willow , ETSE
2.1 Field of use
The Equipment for Cutting and Shredding Energetic Willow, symbolized ETSE, is a technical
equipment of type trailed in transportation and during operation and is designed to operate in aggregated
with wheeled agricultural or forestry tractors with a capacity of approx. 150 hp being actuated from their
PTO. It is used in harvesting and chopping the stalks of energetic willow.
The equipment, Fig. 1 it is mainly composed of the following sub-assemblies: section cutting -
feeding (1), shredder (2), trailer hitch (3), hydraulic installation (4), electrical installation (5), cardanic
transmission (6) and two coupling parts (7).
a) b)
Fig. 1- Equipment for Cutting and Shredding Energetic Willow ETSE-0
-a)- transport position; -b)- working position
The Section cutting - feeding ETSE-1.0 – fig. 2 - it is the subassembly of the equipment that
perform the cutting operation the stems of the energetic willow from the field and their transportation to
the shredder in order of fragmentation in long segments of 15 - 50mm. It consists of: framework (1),
cutting - drag reel left (2), cutting - drag reel right (3), reduction gear box (4), intermediate shaft (5),
transmission shield (6), wall left (7), wall right (8), baffle plate left(9), baffle plate right(10), plants
benter (11), skate (12).
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Fig. 2- Section of cutting – shredding for energetic willow ETSE-1.0
Framework, (fig.3) - is a welded construction made of thick sheet-metal, reinforced with linking
and stiffening elements in rectangular pipe, having the supportive role of all sub-assemblies of cutting-
shredding section.
Fig. 3- Framework
- Cutting - drag reel left – right - is designed to achieve the cutting of energetic willow stalks
and carrying the catted strains to the shredding drum in view of fragmentation. It consists of a central
shaft, equipped with a unidirectional coupling through which is done the actuation of the cutting disc
with the rotational speed of 764 min-1, mounted on the shaft supported by two encapsulated bearings,
from a reduction gear box through a belt pulley and a set of belts SPB type. The entire mobile part is
resting on a support attached to the arm of the shaft, by two radial-axial bearings and one axial, around
which rotates the dragging roller body, receiving movement from the same reduction gear box through a
chain 16A type to a sprocket fixed on the roller body engaging it with a rotational speed of 70 min-1
.
The both hauling rolls oscillates around of a each intermediary shaft on which there are mounted the
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sliding bushings, realizing the space required for the transition of the material cuted in various
thicknesses. Tensioning of rollers in order to maintain its original position (close) is done using a spring.
- Reduction gear box,- is of the type with one input and two outputs with contrary directions of
rotation which receives the movement from the chopper shaft and, by a worm gear with two worm
wheels, reduces the rotational speed from 830 min-1
to 103.75 min-1
, which by means of some chain
sprockets mounted on the shafts of the worm wheels is transmitted to the hauling rollers and determining
at the same time the hauling direction. In addition to this operation, by means of a toothed wheel gear is
multiplied the rotational speed of 103.75 min-1
to the value of 525,234 min-1
, rotational speed which is
transmitted by means of a set of V-belts type SPB and of two belt wheels to the shaft which drives the
energetic willow cutting disc.
It consists of a housing in which is mounted a worm shaft, two worm wheels, on the shaft of which
is mounted the chain wheel, the toothed wheel which drives the pinion on the shaft of which is found the
toothed wheel which drives the pinion on the shaft of which is found mounted the belt pulley and the
lubrication group.
- The intermediate shaft, is the part which allows the oscillation of dragging rollers, getting the
rotation speed of 70min-1
to the dragging rollers and 764min-1
to the cutting discs with a pair of chain
wheels respectively of belt supported by encapsulated radial bearings on a shaft, which is attached on
the support of the cutting section.
- The plants benter, fig. 4,- is a simple construction of bent pipe and has the role to gather the
plants from rows into sheaves, leaning them in front, straining the plants until are cut by of the cutting
disc, preventing their spread until are gripped by the dragging discs and directed to the chopper.
Fig.4 – The plants benter
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The shredder, ETSE-2.0, fig. 5 is the subassembly executing the operation of fragmentation of
energetic willow stalks and throwing of all fragments in a trailer towed by the tractor which ensures the
energetic source of the equipment. It consists of: housing (1) chopper-fan rotor (2) driving group (4),
outlet chimney (5), transport wheels (3).
Fig.5 – The shredder
- The casing, fig.6 is a thick sheet welded construction with the role of supporting the chopping
rotor, transport wheels, cutting equipment, exhausting chimney of shredded material and of rotor driving
group. On the wall of the housing in the close to the feeding mouth are mounted two counter-knives, one
vertically (1) and the second (2), at the bottom of the feeding mouth.
Fig. 6 –Carcasa
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- Rotor-shredder-fan, - within the chopper subassembly is the mainly having the role of
fragmentation of energetic willow stalks that enter into the chopper supply opening , the made of
throwing fragments, transport wheels support, support for rotor driving group and support of deflector
which directs the wood chips to the trailer. It consists of a disc with a thickness of 60 mm and a diameter
of 1150 mm, which has six slots equally spaced radially around which are mounted six plane knives on
one side and six palettes, on the opposite side. the knives execute the fragmentation of the willow stalks
that enter into the supplying mouth and the palettes execute the throwing of the minced material through
the deflector in the trailer. The disc is mounted on a shaft, supported by two oscillating radial bearings
with rollers mounted in two bearings body, which are supported by the housing. shaft has at the entrance
a semi coupling, with grooves representing the semi coupling of a sense coupling. At the output the shaft
is coupled to a cardanic joint, Code 61 311 making the linkage with the reducer and allows the
decoupling of the reducer when the chopping equipment is folded for the intervention to knives and to
the supplying mouth.
- The driving group, fig.7 performs the transmission of the movement from the main reducer
mounted on the drawbar to the chopper rotor by means of a conical reducer (1) with the ratio i=1/1 on
whose shaft at the output is found mounted a three-groove belt wheel (2), which, by means of three belts
SPB type, drives another belt wheel (3), mounted on a shaft, that ends with the inside of a sense
coupling supported by two radial spherical roller bearings, in the housing (4).
Fig. 7 – Driving group
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- The uni-sense coupling, fig.8, is intended to protect the transmission of the chopping rotor as
well as the cutting disc and the one cardanic of shocks caused by the moment of inertia of the rotor at
the decoupling of motion. It is the ratchet type consisting mainly of a hub (1) and a housing (2). It also
has in the composition assemblage elements and driving ratchets.
Fig. 8 – The uni-sense coupling
- The evacuation chimney ETSE-2.3.0, fig.9, is a welded construction that directs the fragments
of willow in the mean of transportation. It consists of : body (1) , a construction in welded sheet metal to
which attaches at the bottom an intermediate body (2) and a deflector at the upper part (3) that regulates
the throwing distance of chopped material by means of a single acting hydraulic cylinder (5), brought to
its initial position by two hauling springs (4)..
Fig. 9 – The evacuation chimney ETSE-2.3.0
- The transportation wheel, fig.10, is intended to provide the transport of the equipment during
operation or transportation. It consists of the complete wheel (1) commercially available, 9.0-15,3
mounted on a shaft (2) on which there is welded a pipe, which is fastened to the chopper housing with
two bolts..
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Fig.10 - The transportation wheel
- The drawbar ETSE-3.0, fig 11, is the assembly which enables the equipment coupling to the
tractor of aggregation. The drawbar is made of laminated profiles welded together realizing the body of
the drawbar (1), being provided at the front with an eyelet of traction (3) necessary for coupling at the
tractor drawbar, a supporting leg when it decoupled from the tractor (2), a conical reducer type Rossi
(4), a cardan shaft with torque limitation coupling (6) and a hook for pulling a trailer for collecting the
chopped material while working (5).
Fig. 11- The drawbar
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2.2. Functional description
The equipment for harvesting and shredding the energetic willow, is so designed as can work
aggregated with a tractor of approx.150 HP commonly used in the Romanian agriculture coupled to the
towing bar of this according to the technological scheme in Figure 12.
Fig.12 - The technological scheme of the equipment for harvesting
and chopping energetic willow - ETSE
The rotation movement from the tractor’s PTO is transmitted to a conical reducer manufactured by
Rossi via a propshaft fitted with friction coupling for torque limitation. From this reducer, with the help
of another cardan rotation is transmitted to a second conical reducer output shaft is mounted on a belt
wheel in the purpose of transmission the rotation movement to the driving group rotor of energetic
willow stalks chopper according to cinematic scheme Fig.13
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Fig.13- Cinematic scheme of the equipment for harvesting and chopping energetic willow -ETSE
Legend:
Symbol No. of
teeth Pitch diameter (mm) Module (mm)
Pitch (mm)
Observations
D1 - 160 - - n1=1000min-1
D2 - 193 - n2=830min-1
D3 - 216 n3=564.6269min-1
D4 - 160 - - n1=764min-1
D41 - 160 N=564.6269min-1
D5 - 172 - - n1=525.234375 min-1
M 4 50 5 - nM=830min-1
Z1 31 155 5 - nz1=103.75 min-1
Z2 45 180 4 - nz2=103.75 min-1
Z3 14 114.146 - 25.4 nz3=103.75 min-1
Z4 20 162.368 - 25.4 nz4=70 min-1
Z5 45 180 4 - nz5=233.4375 min-1
Z6 20 80 4 - nz6=525.234375 min-1
Z7 20 80 4 - nz7=233.4375 min-1
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RT - 460 - - Dragging roll
DT - 750 - - Cutting disc
T - - - - Chopping drum
R1 - - - - Rossi Conical reducer
P01Nsin-200
R2 - - - - Rossi Conical reducer
P01Asin-200
C1:C2 - - - - Cardanic shaft
The rotation movement from the disc of chopper is transmitted to the worm gear of a reducer
which is in gear with two worm gears wheels obtaining their rotation in opposite directions, directions
that must be transmitted and to the cutting discs and to the supplying rollers for the introduction of cut
material into the chopper.
The rotation speed achieved by driving the two worm gears wheels is of 103.75 min-1, speed
which is transmitted to the supplying rollers and the rotation speed that is transmitted to the cutting discs
is of 764 min-1, speed obtained by a multiplication by means of two pairs of toothed wheels mounted in
the reducer.
After the energetic willow cutting equipment is ready for work, it starts the tractor PTO from which the
rotation movement reaches at all the moving parts of the equipment according to the cinematic scheme.
When the tractor is moving, it pulls the equipment that enters in the willow field according to the
technological scheme and starts the bending opperation of plants towards the advancing direction by the
plant bending device, being held in this position until they are cutted by the cutting discs and are guided
towards the dragging rollers, rollers that grab the cutted plants transporting them to the feeding mouth of
chopper. Once the plants reach into the mouth of chopper , they are cut by the knives mounted on the disc
of chopper. The fragmented material get behind the disc through the windows created aligned with every
knife being taken over by the blades mounted behind the disc, palettes representing the fan of chopper.
Once they reach on this palettes, these fragments are driven and thrown through the routing gutter of the
minced material catre un mijloc de transport de se afla in spatele echipamentului. The operation continues
until all the plants cultivated in that plot are cut off and chopped. The cutting process starts from the
outskirts of the plot and continue in circle until the parcel ends up. To start from the middle of the plot to
the outwards must be carry out a path - manually or by other cutting means, path that is required for
entering of the aggregate.
2.3. Dimensional and constructive technical characteristics
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The equipment for cutting and chopping energetic willow has the following dimensional and
constructive characteristics:
- dimensiuni de gabarit:
- overall dimensions:
- length, -in working, mm 3319
-in transportation, mm 5917
- width, - in working, mm 4078
-in transportation, mm 2437
- height, mm 4696
- the cutting disc diameter, mm 750
- the chopping rotor diameter, mm 1150
- the dragging roll diameter, mm 460
- weight, daN 3500
2.4. Functional characteristics
The equipment for cutting and chopping energetic willow aggregated with the tractor has the
following functional characteristics:
- tractor power, HP 150
- tractor PTO speed, min-1
1000
- No. of cutted lines, pcs. 2
- average diameter of cutted willow stalks, mm 40
- maximum diameter of cutted willow stalks, mm 60
- fragments length, mm 15-50
- maximum working width, mm 980
- rotation speed of the rotor with discs, min-1
764
- rotation speed of the dragging rollers, min-1
70
- rotation speed of the rotor with knives of the chopper, min-1
830
2.5. Conditions of achievement
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EM of this equipment was conducted by specialized personnel from Mechanical Ceahlăul.
According to the staff list, was appointed the working group.
At first it was analyzed the execution project concerning the composition, functional and
kinematic scheme, were identified the main raw materials and materials required, has been drawn up the
documentation of manufacturing technology (technological sheets, consumption of materials), has been
drawn up the mounting technological documentation, have been identified the potential suppliers of raw
materials and materials and then was carried the supply with raw materials and materials.
The raw materials and materials supplied for the execution of experimental model were received
on the basis of the accompanying documents of the goods. Certificates of quality on raw materials and
materials taken into store were highlighted in an registry entries existing at the warehouse shopkeeper.
Have not been supplied non-conforming raw materials and materials.
The subassemblies from collaborations were received by the head of the Executive
Departmenton the basis of the quality certificate that has been properly completed by the supplier. The
subassemblies quality certificates are kept by the head of the Executive Department.
Were supplied and used from the mass production the following components: transport wheels,
gearboxes Rossi, gimbals, cutting discs, hydraulic hoses, V belts, beaded chains, bearings, cables and
removable fasteners such as: screws, nuts, flat washers, spring washer, etc..
During the activity of execution of the technical equipment, where appropriate, has been taken into
account of the standards and regulations in force.
The consultancy and technical assistance to the execution of parts and sub-assemblies of the
experimental model has been provided by the specialists from INMA Bucharest - RDI DEPARTMENT:
Research, Development and Innovation.
The housings and gear wheels, the reducer component parts were executed at manufacturers
specialized in casting operations, processing and heat treatment for gears. The disc of shredder was
constructed at a manufacturer specialized in the realization of such parts, it dealing inclusively with the
dynamic balance of the part that has a very large inertial mass (the part weight is of 460 daN).
Were not necessary speciality aprovals.
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The mode to disseminate the results.
On May 20, 2013 was held in Piatra Neamt the Symposium "Energetic Willow, an alternative for
agriculture and important source of renewable energy".
It was presented the work: Promotion in Romania of the technology for cultivating the
energetic willow (SALIX VIMINALIS) as an alternative source of clean energy - Planters,
harvesters and shredders for energetic willow.
Have been submitted two patent applications: A 00977/10.12.2012 and A 01029/18.12.2012.
Director of project
Dr. eng. Gageanu Paul
