Pellets: Howtomakemore fromyour woodchips and sawdust

Transcription

1 Your experts in biomass pelleting Pellets: Howtomakemore fromyour woodchips and sawdust

2 INDEX 1- THE COMPANY 2-MARKET POTENTIAL IN THE WEST COAST 3-CASE SCENARIO: FEASIBILITY STUDY OF A 100,000 mton/y PELLET PLANT 4-WOOD PELLET PRODUCTION PROCESS 5- SOME OF OUR REFERENCES

3 1. The company

4 THE COMPANY PRODESA is an engineering and manufacturing company specialised in the supply of turnkey pellet plants worldwide. CORE BUSSINES: Design and supply of turnkey plants. PRODESA is a global partner for complete pellet plants, biomass dryers and biomass fueled CHP plants. PRODESA has a sister company that takes care of the O&M contracts: SMART OPERATIONS. With its headquarters in Spain and branch offices in the US, Russia, France and Malaysia. More than 20 years of experience in the development of biomass plants and pellet plants. References between 20,000 mton/y and 460,000 mton/y

5 THE COMPANY The team of professionals that make up the workforce of PRODESA make it possible to cover all the stages of the project: Promotion and feasibility studies Basic and detailed engineering Manufacturing Assembly Start-up Training Technical after-sales assistance Plants and Operation

6 THE COMPANY Proven track record manufacturing and building pellet plants in different latitudes, climates and wood species. PRODESA is Not the standard EPC company, PRODESA is Specialized in pellets plants, so the customer benefits from all the advantages of experience and specialization.

7 PRODESA has a Strong Engineering Team in order to do all the process and manufacturing engineering in house. THE COMPANY PRODESA does the Automation & Programming in house.

8 THE COMPANY: INTERNATIONAL PRESENCE

9 WE BELONG TO

10 2. Market Potential in the West Coast

11 ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus H. Masaki Mita, Head of Japan Office, ARGUS

12 ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus H. Masaki Mita, Head of Japan Office, ARGUS

13 ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus H. Masaki Mita, Head of Japan Office, ARGUS

14 FUTUREMETRICS PRESENTS TWO DIFFERENT SCENARIOS: Source: Bill Strauss, President of Futuremetrics. Pellets Fuel Institute Conference 2016.

15 FUTUREMETRICS PRESENTS TWO DIFFERENT SCENARIOS: Source: Bill Strauss, President of Futuremetrics. Pellets Fuel Institute Conference 2016.

16 3.Case Scenario: FeasibilityStudyof a 100,000 mton/y Pellet Plant

17 JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL PELLET TONS mtons PELLET TON PRICE $/mt REVENUE $ $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $16,000,0 COSTS OF GOODS SOLD RAW MATERIAL RAW MATERIAL mtons RAW MATERIAL COST $/mton COGS MATERIALS $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $5,400,0 FUEL FUEL mtons FUEL COST $/mton COGS FUEL $ $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $798,0 ELECTRICITY CONSUMPTION kwh/ton ELECTRICAL COSTS $/kwh ELECTRICAL COSTS TON $/ton COGS ELECTRICITY $ $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $1,169,3 LABOR NUMBER OF SHIFTS WORKERS PER SHIFT TOTAL WORKERS GROSS MONTHLY SALARY $ SALARY $ CENTRAL SHIFT WORKERS GROSS MONTHLY SALARY $ CHIEF SALARY $ LABOR COSTS $ $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $850,0 PACKAGING BAGGING COST PER TON $/ton PALLET COST PER TON $/ton PACKAGING COSTS $ $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 MAINTENANCE COSTS SPARE AND WEAR PER TON $/ton MAINTENANCE COSTS $ $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $517,5 TOTAL COGS $ $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $8,734,8

18 JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL EXPENSES OCCUPANCY EXPENSES Insurance $ Maintenance $ Property Tax $ Rent $ Utilities (Water/Waste/Etc) $ TOTAL OCCUPANCY $ PAYROLL EXPENSE Wages $ Salaries $ Payroll Tax $ Workers Comp $ Employee Benefits $ TOTAL PAYROLL $ OPERATING EXPENSE Automobile $ Banking $ Computer $ Dues and subscriptions $ Equipment rental $ Fuel $ Insurance $ Miscellaneous $ Office Supplies $ Repairs and maintenance $ Shop tools and Suppliers $ Travel and Entertainment $ TOTAL OPERATING EXPENSE $ TOTAL EXPENSE $ $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $710,640 TOTAL COST COGS + EXPENSES $ $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $9,445,468 NET INCOME $ $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $6,554,532

19 JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL MEMO INPUTS tons PELLET TON PRICE $/t REVENUE $ $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $16,000,000 COSTS OF GOODS SOLD COGS MATERIALS $ $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $5,400,000 COGS FUEL $ $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $798,000 COGS ELECTRICITY $ $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $1,169,328 LABOR COSTS $ $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $850,000 PACKAGING COSTS $ $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 MAINTENANCE COSTS $ $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $517,500 TOTAL COST GOODS SOLD $ $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $8,734,828 EXPENSES TOTAL OCCUPANCY $ $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $71,100 TOTAL PAYROLL $ $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $288,900 TOTAL OPERATING EXPENSE $ $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $350,640 TOTAL EXPENSES $ $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $710,640 TOTAL COST COGS + EXPENSES $ $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $9,445,468 NET INCOME $ $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $6,554,532 DEBT SERVICE DEBT SERVICE $ $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $1,907,577 NET INCOME - DEBT SERVICE $ $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $4,646,955

20 SUMMARY: INPUTS Price of pellets: 160 $/mton Price of raw material: 30 $/mton Price of fuel: 30 $/mton Price of electric energy: $/kwh Labor costs: 40,000 $/year base worker 50,000 $/year foreman

21 SUMMARY: OUTPUTS Annual revenue: 16,000,000 $ (sales of pellets) COGS (cost of goods sold): Annual raw material cost: 5.400,000 $ (57.15%) Annual fuel cost: 798,000 $ (8.45%) Annual Electric cost: 1,169,328 $ (12.38%) Annual labor cost: 850,000 $ (9.0%) Annual maintenance cost: 517,500 $ (5.48%) Total annual COGS: 8,734,828 $ EXPENSES: Total Annual Expenses: 710,640 $ (7.52%) Net Income: Revenue COGS Expenses: 6,554,532 $ Debt Service: 1,907,577 $ (25% Equity, 5% interest rate, 15 years) Net income Debt service: 4,646,955 $

22 4. Wood pellet production process

23 LOGS CHIPS SAWDUST RAW MATERIAL COGENERATION WITH ORC Hot water DEBARKER DRUM CHIPPER HAMMER MILL BELT DRYER DRY PRODUCT STORAGE PELLETS PELLETING LINE BUFFER SILO MILLING LINE

24 PRELIMINARY LAYOUT

25 WOOD PELLETS PRODUCTION Raw material storage

26 WOOD PELLETS PRODUCTION Wood handling line DEBARKER CHIPPER WET HAMMER MILL

27 WOOD PELLETS PRODUCTION Drying line PRODESA manufactures its dryers under the license of the Swiss brand W. Kunz drytec AG, leader in the developement of thermal dryers which markets its products under the brand Swiss Combi since more than 40 years. DRUM DRYER HIGH TEMPERATURE BELT DRYER LOW TEMPERATURE Drying technology under the license of

28 WOOD PELLETS PRODUCTION Dry product storage Moisture content homogenization Flexibility in working hours: drying vs pelletizing Mechanical durability PELLET QUALITY

29 WOOD PELLETS PRODUCTION Milling line

30 WOOD PELLETS PRODUCTION Pelleting line

31 WOOD PELLETS PRODUCTION Pellet storage silos

32 WOOD PELLETS PRODUCTION Bagging and palletizing line

33 WOOD PELLETS PRODUCTION Supply of thermal energy BIOMASS FURNACE / HOT WATER BOILER BIOMASS CHP PLANT OTHERS: Residual energy(water steam, hot water, hot gases coming from other applications)

34 WOOD PELLETS PRODUCTION CHP Plants Our pellets plant design allow us to associate the pellets production to power generation by ORC system. This kind of plants increases the efficiency and feasability of project, becoming more profitable the economic investment.

35 WOOD PELLETS PRODUCTION Plant control and programming

36 WOOD PELLETS PRODUCTION Plant control and programming

37 5. SOME OF OUR REFERENCES

38 AVOTI High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant Latvia ton/year Logs,chips, sawdust and shavings Industrial-Residential I1-A1 Yes (by the customer) PROCESS DATA Pretreatment Drying technology Dryer size Pellet capacity Debarking, chipping and milling Belt dryer 240 m2 15,9 tn/h Number of pellet mills 3 PELLETS OUTPUT Pellets storage Loading system 2 x 500m3 each By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT

39 ERTA Wood pellet plantand CHP plant GENERAL DATA Location Tarazona de la Mancha, Albacete (SPAIN) Pellet plant capacity ton/year Raw material Logs, woodchips and sawdust Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC CHP 7 (by the customer) PROCESS DATA Pretreatment Debarking, chipping and milling Drying technology Belt dryer Dryer size 84 m2 Pellets capacity 8 ton/h Number of pellet mills 2 Electrical power capacity 680 kw PELLETS OUTPUT Pellets storage 4 silos x 500 m3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT

40 GRANORAMA High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant PROCESS DATA Pretreatment Drying technology Dryer size Dryer evaporation capacity Dryer thermal consumption Pellet capacity Number of pellet mills 6 PELLETS OUTPUT Pellets storage Truck loading system Rail loading system Lithuania ton/year Logs, chips and sawdust Domestic EN PLUS A1 No Debarking, chipping and milling Belt dryer 2 x 212 m2 21,8 ton/h kw hot water 90-60ºC 26 ton/h 4 vertical silos m3/unit 3 vertical silos m3/unit Yes Yes

41 GALPELLET Wood pellet plant and CHP plant GENERAL DATA Location Galicia (SPAIN) Pellet plant capacity ton/year Raw material Woodchips Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC CHP 6 PROCESS DATA Pretreatment Wet milling Drying technology Belt dryer Dryer size 66 m2 Pellets capacity 3 ton/h Number of pellet mills 1 PELLETS OUTPUT Pellets storage 2 silos x 88,000 ft3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT

42 GENERAL DATA GREEN PELLET SARAWAK High capacity wood pellet plant Location Pellet plant capacity Raw material Primary end market Cogeneration plant PROCESS DATA Pretreatment Drying technology Dryer size Dryer evaporation capacity Dryer thermal consumption Pellets capacity Biomass boiler PELLETS OUTPUT Pellets storage Truck loading system Rail loading system Port investments Bintulu (MALAYSIA) ton/year Acacia chips and waste veneer Co-firing in South Korean utilities No Chipping Belt dryer 157 m2 7,7 ton/h kw 20 ton/h kw Vertical silos 500 m3 Yes No No

43 GREEN PELLET SARAWAK High capacity wood pellet plant

44 RIBPELLET Wood pellet plant and CHP plant GENERAL DATA Location Huerta del Rey, Burgos (SPAIN) Pellet plant capacity ton/year Raw material Logs and sawdust Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC kwe (by the customer) PROCESS DATA Pretreatment Debarking + chipping + milling Drying technology Belt dryer Dryer size 140 m2 Pellets capacity 8 ton/h Number of pellet mills 2 Electrical power capacity kwe PELLETS OUTPUT Pellets storage 10 cells x 200 m3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT

45 COLOMBO ENERGY (PORTUCEL Group) High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant Greenwood County, South Carolina (USA) ton/year Logs and woodchips Industrial (European utilities) I2 No PROCESS DATA Pretreatment Drying technology Pellet capacity Debarking, chipping and milling Drum dryer 70 ton/h Number of hammer mills 5 Number of pellet mills 15 PELLETS OUTPUT Pellets storage Loading system 2 silos By rail PRODESA s ACTIVE ROLE (Milling and Pelleting line TURNKEY)

46 COLOMBO ENERGY (PORTUCEL Group) High capacity wood pellet plant

47 Forcus Martínez Sales Manager