Production of big straw bales, straw pellets, transport and storing for power plants and CHP plants

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1 Fact sheet 12 - Denmark Production of big straw bales, straw pellets, transport and storing for power plants and CHP plants This fact sheet describes the production of straw pellets in Denmark, as well as the large scale delivery of straw bales to CHP plants (Combined Heat and Power plants) and power plants. In 2005 the total amount of straw used for energy in CHP and power plants was 650,000 tons, of which 65,000 tons was used as pellets in one power plant. Straw pellet storage at the pellet plant. At a traditional condensing power plant, 40 48% of the energy input is converted to electrical power. The remaining energy is cooled away in the river, the see or in a cooling tower. In a CHP plant the remaining energy is cooled by the district heating net in a nearby larger town. This system increases the total efficiency to 85 90%. The Danish Government introduced the CHP policy in The policy included the use of domestic fuels, primary biomass in the CHP plants. Additionally, the power plants in Denmark, mainly coal fired plants, have during several decades been converted to combined heat and power plants, but they are larger, and the primary production is electricity. The CHP plants are quite small, they use domestic fuels and have to optimize both the electricity production and the district heating production. Supply chain for straw pellets to power plants No 12 1

2 Straw fired CHP plants commissioned in the period 1989 to Since 2000 no plants are commissioned. All plants are using big bales. CHP plants Unit Rudkøbing Haslev Slagelse Masnedø Grenå Måbjerg Maribo Elec. power MW Heat output MJ/s Steam pressure Bar SH temperature ºC Power plants with straw firing. Studstrup 4 is co-fired coal/straw 90/10%. Ensted has a wood-fired superheater. Avedøre 2 consist of 2 boilers with a mix of oil, gas, wood and straw. Amager is 100% straw pellets. Odense will in 2009 be 100% straw bales. Studstrup and Amager are converted from older coal boilers. Power plants Unit Studstrup 4 Ensted Avedøre 2 Amager Odense Elec. power MW Heat output MJ/s Steam pressure Bar n.a. SH temperature ºC n.a. The emission requirements for the CHP plants are individual, and approvals are in the following range: CO: from 0.05% (625 mg/nm 3 )at 10% O 2 to none Dust: from 40 to 50 mg/nm 3 NO x : from 400 mg/nm 3 to none SO 2 : from 300 mg/nm 3 to none Danish straw pellet plant. The bales are conveyed to the string remover and the scarifier to the left. Supply chain for straw pellets to power plants No 12 2

3 Raw material availability The production of straw in Denmark was 5.5 million tons in The main grain types are wheat and barley. In 1990 burning of straw in the fields was banned, mainly due to environmental reasons. Today, most harvest combiners are equipped with a scarifier (chopper) which chops the straw if there is no use for the straw on the farm or for energy purposes. The scarified straw can immediately be ploughed in and serves as fertilizer and for some soil types as soil improvement. The table "Straw production 2005" shows that there are still biological resources of 2.3 million tons for an increased energy use of straw. The techno-economical resource is of course smaller. Some fields are small and not well suited for large machinery. Some soil types need the straw to be ploughed in for soil improvement, and some farmers are not interested in producing straw bales to the actual market price. The straw price has been stable in fixed prices for more than 15 years. But some hundred thousands of tons can be taken out for energy use if new plants are build in the actual market and price situation. Production and use of straw in Denmark Source: Statistics Denmark. Straw production tons Use on farms 1,900 Energy purpose 1,300 Ploughed in 2,300 TOTAL 5,500 Use of straw for energy purpose in Denmark Source: Danish Energy Authority. Straw for energy tons Central power plants 460 CHP plants 250 District heating 260 Industry 0,5 Farms and houses 330 TOTAL 1,300 Production technology and methods Large-scale straw handling for energy purposes has developed into an independent discipline in agriculture in which particularly large farms and machine pools make investments. The big bale WxHxL: 120x130x240 cm is the only type accepted by CHP and power plants. The weight is around 500 kg, and new balers can make bales up to 700 kg Production technology and methods for big bales delivered to straw pellet plant, CHP plant and power plant Process Description Machines used Harvesting of wheat, rye, Straw is a waste product from cereal grain production. Combined harvester barley, triticale and oats Drying/raking/turning of After rainfall the swath has to dry. Raking and turning is Tractor, raker swaths important for the straw quality if rainfall occurs. Baling Big baler for kg/bale. Capacity tons/hour. Bale density kg/m 3. Tractor, baler, accumulator for bales Loading in the field Transport to the farm Unloading at the farm Large tractor with front end loader for 2 bales loads the bales to the trailers in the field. Medium size tractor to haul the trailers. Storing at the farm Transport to the pellet plant, CHP plant and power plant Unloading at the pellet plant, CHP plant and power plant Straw is stored indoor and outdoor. Indoor storage keeps the moisture content stable and prevents mould. The capacity for large storage is tons/m 2. Outdoor storage is cheap, but is mainly for short term storage. Needs covering with tarpaulin. Large tractor with front end loader for 2 bales loads the bales to the truck at the storage. The truck has to carry 12 bales and also 12 bales on the trailer in two layers. The bales have to be covered with a net to prevent straw loss at the roadside. A crane on the plant is equipped with grip hooks that can lift 12 bales (one layer) at a time off the truck. By means of microwaves that are sent through the bales from one grip hook to the other one, and by means of a weighing cell between grip hooks and crane, the average water content and the weight are being measured and recorded by a computer. Tractor with front-end loader. Tractor with farm trailers. Telescopic handler for the storage at the farm. Tractor with front-end loader. Truck specially equipped for straw transport. Telescopic handler for the storage. Crane for unloading 12 bales in one operation. Weighing cell for 12 bales. Equipment for 3 micro wave measurements per bale for moisture content. Supply chain for straw pellets to power plants No 12 3

4 Truck for long distant transport at the pellet plant. The net is used to prevent loss of straw at the roadside. Production technology and methods for production, storing and handling of straw pellets Process Description Machines used Scarifying, milling The strings around the bale are removed before chopping (scarifying) to 3 8 cm pieces. The hammer mill divides the straw further down. String remover, scarifier, hammer mill conveyors Pelletising The pellet press has a ring die or a flat die with holes in the die between Pellet press ø6 to ø12. 2 rollers are pressing the straw through the holes. Steam is added to heat the lignin in the straw to be used as glue. Cooling The pellets need cooling before storing in order to prevent condensing Band cooler and swelling. Storage The pellet are stored in large heaps Conveyors, dumpers Transport to enduser From the pellet plant the pellets are transported to end user as bulk commodity or in big bags. Dumpers, conveyers, trucks, ships, trains Unloading 12 bales in one operation. The crane takes 12 bales to the straw storage. Supply chain for straw pellets to power plants No 12 4

5 Production costs The calculations are divided into a calculation for straw bales delivered to the pellet plant and a calculation for production of straw pellets. Cost type Eurocents/GJ Bales 421 Pellets 558 Total costs 979 Calculation of production costs for straw in big bales with 14.5 GJ/tons heating value at 15% moisture. Source: Landscentret Cost type Bales Price level in Eurocents/GJ Average in Eurocents/GJ Value of straw in the field Turning Baling Loading, transport, unloading Storing at the farm Insurance Other costs Calculation of risk Profit N/A N/A TOTAL The conditions for the figures in the pellet table are: Pellet plant capacity: 10 tons/hour Annual operation: 6000 hours Depreciation machinery: 7 years Depreciation buildings: 15 years Interest: 7% p.a. Investment: 6.9 million euros Calculation of production costs for straw pellets. Source: Fuels for CO 2 reduction in power plants. Danish Technological Institute Cost type Pellets Price level in Eurocents/GJ Capital costs Machine depreciation 57.9 Building depreciation 22.6 Interest 28.6 Variable costs Staff salary 48.4 Spare parts 26.4 Electricity 61.6 Straw transport to pellet plant Insurance, water etc. 8.8 Administration, profit Fuel for steam 17.6 Interest of pellet storage 22.0 TOTAL Business organization including staff requirements Straw production The Danish farms are privately owned. This corresponds to a family running a farm with hectare producing pigs, milk, grain, or other specialized products. Most farmers are specialized in either pig production or milk production or only production of cereals without animals on the farm. The farming sector is highly industrialized with a high level of mechanization and with few people occupied. Most farmers with a straw contract produce several hundred tons of straw annually. A few large farms and machine pools have developed large scale handling of 10 30,000 tons of straw annually. Manpower required for the straw supply chain from the field to the plant. Source: Straw for Energy Production. The Centre for Biomass Technology. Denmark Operation Manpower in manminutes/tons Manpower in manhour/tj Turning / raking of swath Baling Loading in the field Transport to the farm Unloading at storage Loading at storage for the plant Transport to the plant. Truck Unloading at the plant Total Supply chain for straw pellets to power plants No 12 5

6 Large scale outdoor storage of straw for energy purposes. Straw pellet production The use of straw pellets in Denmark is a closed circuit as both the pellet plant and the power plant using the pellets is owned by the same utility company. This means that there is no commercial market for straw pellets and no market price. The actual pellet plant is designed for a production capacity of 130,000 tons/year as a demonstration plant. Up to now (2006) the annual production is 65,000 tons. At a standard pellet plant with an annual production of 60,000 tons/year the man power requirement will be 8 persons. Hopper used by unloading ships for pellets and coal at the power plant Heavy conveyor at the harbour for loading straw pellets into ships Supply chain for straw pellets to power plants No 12 6

7 Marketing and contracting For straw used in pellet production the utility company invites public tenders for straw delivery. Main conditions could be like: Bale size: Width: m. Height: m. Length: m. Bale weight: between 400 and 1100 kg Moisture content 10 18%, but as low as possible. Bales placed in a special way on the truck and trailer at delivery for unloading by crane. The farmer has to deliver straw throughout the year. The plant specifies the timetable for delivery. Straw from wheat, rye, barley can be delivered. No visible mould on bales by delivery. Fuel quality and control of fuel quality The dry matter in straw consists of around 50% carbon, 6% hydrogen, 42% oxygen and minor amounts of nitrogen, sulphur, alkali (sodium, potassium) and chloride. The presence of chlorine and alkali in the flue gas is problematic, since these matters undergo chemical reactions into sodium chloride and potassium chloride that are extremely corrosive in respect of the steel of the boiler, particularly at high temperatures. According to CEN/TS the specification of origin is typical: Cereal crop straw Traded form: Pellets. The specifications of properties are: Dimension: D08 Moisture: M10 Ash: A06 Sulphur: S0.10 Mechanical durability: DU95 Amount of fines: F1.0. Pellet mechanical durability: ASME 269 (CEN/TS ). The quality control of the bales at the plant is visual control of mould. Weighing and measuring the moisture content are done automatically. If the average of the moisture content is over 13% the load is reduced with 2% for each % the water content is over 13%. And thereby the price for the load is reduced, as the payment unit is DKK/tons. If the average is over 23% for two bales, the load will be rejected. If the average of the moisture content is under 13%, the load is increased with 2% for each % the moisture content is less than 13%, but only to 10%. Recommendation of suitability of the method in other countries or sectors Large scale outdoor storage stacked by using a telescopic handler. Supply chain for straw pellets to power plants No 12 7

8 It is a prerequisite that there is established a market for straw for energy use. The described method for straw production and pellet production is easy to use in other countries with a highly mechanised agricultural sector and where the subsidy and tax system favour a CO 2 - neutral energy production. Most Danish straw-fired CHP and power plants have received subsidies to the cost of construction and get subsidies to the electricity production. Without these subsidies only a very small amount of straw would have been used for energy purposes in Denmark. Circular silo for pellet storage at a Danish power plant. Produced by Danish Technological Institute Centre for Renewable Energy and Transport October 2007 The sole responsibility for the content of this fact sheet lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein. Supply chain for straw pellets to power plants No 12 8

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