C: AVA Nigeria Flash Drying ExperienceSanni, L O., A. Marchant, A. Graffham, L. A. Abayomi, B. Siwoku, K. Adebayo, A.
Westby , Mfregene, O. Adewolu, G. Asumugha, E. Alenkhe, T. A. Diallo, C. Iyangbe, A. Raji, R. Edosio,, E. I. Kwaya, N. Akobundu, A. O. Afowowe, I. C.
Ozumba, O. T. Odunjo, W. B. Asiru, A. Babatunde, E. Obinna, . C. H. Kadurumba, R. Omolehin, A. C. Iheanacho, S. Bamire, I. Ojiakor, Ojobo, R. Edosio, M., Nkang
Partners:
Funded by the Bill and Melinda Gates Foundation
What is a Flash Dryer?
Flash dryer is a continuous drying plant used for drying variety of wet cakes by disintegrating wet cake into fine powder and dried by hot gas to form powder.
Drying is carried out in a short span of time usually 0.5 to 3 seconds.
Flash dryer is versatile. It could be to produce starch, HQCF, complementary foods from cassava and other root crops.
Notable organisations in Nigeria that has promoted usage of FDs are FIIRO, IITA working with Octec, Peak & Nijilucas improving on the performance of the FDs.
2008 Inefficient Costly Processing
• 156 flash-dryers (FD) in 127 SME’s
• 86% of FD’s poor – 11% efficiency, Output 103kg/hr 374 litres diesel/tonne
• 14% FD’s - 32% efficiency, Output 96kg, 132 litres diesel per tonne
• International standard: Efficiency 50%, 200kg/hr 76-80 litres diesel per tonne
Are all flash dryers the same?
Name of flash dryer
Output kg dry product /hr
Diesel per ton dry product
Efficiency %
NX4-CY 202kg 87 litres 49%
NX2-CY 96kg 132 litres 32%
NSD2-CY 105kg 139 litres 30%
NX1-CY 119kg 166 litres 25%
China-FD 99kg 313 litres 13%
NP1-CY 103kg 374 litres 11%
Working with Flash Dryer Manufacturers and SMEs
• Fabricators: Niji Lukas Limited; NOBEX Limited; Peak Precision Ltd ready to retrofit.
• Assessed SMEs: Mic Makin, Akure; Peak Products, Abeokuta, Godilogo Farms, Obudu, Cross Rivers, Eagle Baba SME at Osogbo.
Significant improvements to flash drying
• Old dryers used 199 l diesel per t HQCF• Newly designed Nobex 4 uses 86 l/t (49%
efficient). Cost reduction ca. $130/t- 50% fuel cost reduction
• Changes (fans/heat exchangers) to commercially-produced equipment consequence of C:AVA assessments.
• Modifications to design: a result of C:AVA intervention
CAPACITY STRENGTHENING OF LOCAL FABRICATORS: NOBEX SUCCESS STORY
Assessed October 2009: the Nobex Double Cyclone Dryer had the best overall performance of 10 dryers tested in Nigeria and Ghana
Assessed October 2009: the Nobex Double Cyclone Dryer had the best overall performance of 10 dryers tested in Nigeria and Ghana
June 2010: Nobex Four Cyclone Flash Dryer was assessed and adjudged to be the highest efficiency drier assessed to date
June 2012 2011: To deliver 4-cyclone to Malawian client courtesy C: AVA.
January 2012: Nobex obtained contract to deliver 4 Cyclone Flash Dryer to Lagos State Government Cassava Development Project.
CTAP-NRCRI-IITA-NARs-C:AVA SME Audit
Average Cassava Roots Cost per HQCF per Zone
41,33352,000
39,60052,800
0
10,000
20,000
30,000
40,000
50,000
60,000
North Contral South East South West South South
Geo-political zone
Co
st
Average Cost of Fuel for Drying per Zone
7,050 8,200
12,58614,024
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
North Contral South East South West South South
Geo-Political Zones
Co
st
CTAP 14 Engineers & 1 Socio – Economists audited 157 SMEs, Feb –March, 2012
Assessment of the cost element HQCF FDs
Cost Element Percentages in South West
50%
0%3%1%1%1%0%
16%
3%
2%
5% 8%6%
1%
3%
Cassava Roots
HQCF Wet Cake
Peeling
Grating
Dewatering bags
Pressing (De-watering)Electricity
Fuel for Drying(Black oil)Generator
Pulverization to fuelflourPackaging-bags
Transport to market
Fixed Cost
Water(fetching/production)Contingencies (3%of fixed + var. cost
Cost Element Percentages in South East
64%0%5%
1%1%1%1%
10%
1%
1%
3%
2%
5% 2% 3%
Cassava Roots
HQCF Wet Cake
Peeling
Grating
Dewatering bags
Pressing (De-watering)
Electricity
Fuel for Drying(Black oil)
Generator
Pulverization to fuelflour
Packaging-bags
Transport to market
Fixed Cost
Water(fetching/production)Contingencies (3%of fixed + var. cost
Cost Element Percentages in South South
50%
0%5%2%2%1%3%
13%
6%
1%
3%
6% 5%
0%
3%
Cassava Roots
HQCF Wet Cake
Peeling
Grating
Dewatering bags
Pressing (De-watering)
Electricity
Fuel for Drying(Black oil)
Generator
Pulverization to fuelflour
Packaging-bags
Transport to market
Fixed Cost
Water(fetching/production)Contingencies (3%of fixed + var. cost
Cost Element Percentage in North Contral
56%
0%4%2%0%2%0%10%3%
1%
4% 8%6%
1%
3%
Cassava Roots
HQCF Wet Cake
Peeling
Grating
Dewatering bags
Pressing (De-watering)
Electricity
Fuel for Drying(Black oil)
Generator
Pulverization tofuel flour
Packaging-bags
Transport tomarket
Fixed Cost
Water(fetching/production)Contingencies (3%of fixed + var. cost
C: AVA Upgrade Strategies
To Upgrade 25 out of 157 FDs in Nigeria ($8,000 for an SME) – 41% efficiency, Output 138kg/hr, 103 litres diesel per tonne
Open days for SME’s to promote FD upgrade, present financials (business plan based) & industry essentials (QA & markets)
Training and monitoring of QA among SME’s
Strengthening market linkages / end user support
Key Messages
Product from the FD to be price competitive
Reduction of cost of fuel is achievable
Profitability of HQCF depends on cassava root and drying costs
Quality Assurance is key
North-South Collaboration is very important in equipment development
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