THERMOECONOMIC ANALYSIS OF ELECTRICITY COGENERATION FROM SUGARCANE ORIGIN.
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1 Third Biomass Conference of the Americas Montreal, August 24-29, 1997, Elsevier Science Ltd. Vol. II - PP THERMOECONOMIC ANALYSIS OF ELECTRICITY COGENERATION FROM SUGARCANE ORIGIN. Suani T. Coelho, Institute of Eletrotechnics and Energy (USP) Av. Prof. Almeida Prado, São Paulo - Brazil Silvio de Oliveira Junior, Technological Research Institute (IPT) and Polytechnic School of the University of São Paulo C.P. 7141, São Paulo - SP David Zylbersztajn, IEE/USP - Energy Secretariat of the State of São Paulo Rua Bela Cintra, São Paulo - Brazil ABSTRACT Most Brazilian sugar/alcohol industries are energy self-sufficient and, in the State of São Paulo, some of them even export electricity surplus to local utilities. However, despite the huge potential of electricity surplus to be generated, there are still difficulties to be solved. One of these main problems is the sale s price of electricity. Despite the advantages of sugarcane origin electricity both for electric sector and alcohol industries, they do not agree about the sale s price and most industries are not interested on selling electricity, considering too low the price offered by local utilities. This paper evaluates the cost of the electricity surplus for real plants, using thermoeconomic analysis. Different cogeneration systems are considered and the corresponding electricity costs are evaluated, being compared to the current electricity marginal cost of Southeast Brazil. From obtained results, mechanisms are proposed to improve the existing cogeneration program, aiming to accomplish its initial objectives. KEYWORDS Biomass; cogeneration; thermoeconomic analysis.
2 INTRODUCTION The National Alcohol Program (Proalcool) is well-known as being the largest program of commercial biomass utilization in the world. In last harvesting season, 273 million tones of sugarcane were crushed, leading to 13.5 million tones 1 of sugar and 13.7 billion liters of ethanol (Macedo, 1997). However, it presents nowadays significant economic difficulties mainly due to the lack of economic competitiveness of alcohol compared to gasoline, among others. So, electricity surplus, produced by alcohol industries and sold to local utilities, would diversify sugar/alcohol sector, as well as it would allow electric sector to guarantee electricity offer 2. Brazilian electric sector has been facing significant difficulties during last decades and electricity consumption has grown more than twice from 1979 to Because Brazilian generation system presents highly seasonal characteristics due to its hydroelectric origin, sugarcane origin generation could be used as complementation for the dry period 3, instead of thermoelectric power plants, with the environmental advantage of replacing fossil fuel by biomass. However, there are still several barriers (Coelho and Zylbersztajn, 1996) to implement a large scale electricity generation program from biomass origin. One of the main difficulties is the sale s price of electricity surplus to the grid. There is a protocol ( Program for Cogeneration and Electricity Self-production in Sugar/Alcohol Sector of the State of São Paulo ) signed in 1993, between São Paulo Government (utilities) and sugar/alcohol producers. This contract establishes that the purchase price of electricity surplus is limited by the marginal cost (nowadays US$ 38/MWh, according to Eletrobrás, ), but utilities offer a much lower price and so most industries are not interested on selling electricity to the grid 5. In 1995, only 96 GWh were bought by São Paulo utilities, against 79,220 GWh of electricity consumption in the state. Aiming to collaborate to such discussion, this paper evaluates the cost of the electricity surplus generated in the alcohol plant, for different configurations with conventional systems, from an existing study for a real alcohol plant in the State of São Paulo (Copersucar, 1991). Obtained results are compared to the current 1 Metric tones 2 Bagasse production during last season corresponds to an energy content equal to GJ, on LHV basis. 3 Corresponding to the harvesting season. 4 Despite controversies among specialists regarding this figure (Coelho and Zylbersztajn, 1996) 5 Most contracts have a price around US$ 11/MWh.
3 generation costs of the chosen plant and also to the local expansion marginal cost proposed by Eletrobrás. METHODOLOGY In a cogeneration plant, like a sugar and alcohol mill, the combination of the exergy analysis (combination of energy and entropy analysis of thermal systems) with cost partition methods allows to evaluate rigorously the production costs of electricity and steam, because the exergy concept evaluates differently work (pure exergy) and heat. This study utilizes thermoeconomic analysis, based on the concept of exergy, to compare electricity and steam cogeneration costs in the chosen sugar/alcohol plant. The cost partition methods adopted are the equality and electricity as by-product ones, with the following considerations: the evaluation of base case (current plant situation) considers that electricity and steam specific generation costs (exergy-based) are equal. This assumption means that the alcohol plant does not aim to sell electricity to the grid, what indeed corresponds to most cases in Brazil; its main purpose is just to be energy self-sufficient in steam and electricity needs; the evaluation of electricity costs when more efficient technologies are introduced - to generate electricity surplus - assumes that steam specific cost is equal to the base case one. From the obtained electricity costs, sale s price of electricity surplus is also evaluated, assuming that electricity costs for the alcohol plant are equal to the cost of the base case one; in all cases, excess bagasse (when existing) is sold 6 and the obtained revenue is considered when evaluating energy costs. The chosen plant crushes 300 tones of sugarcane per hour, in average, with current consumption of 24 kwh/tc of electricity and 465 kg of low pressure steam per tone of cane (tc) 7. To evaluate energy generation costs, the following assumptions were made: interest rate: 15 per year; 20 years lifetime (financial conditions usually employed by industrial sector); bagasse opportunity price equal to US$7.5 per tone of 50 wet bagasse; 6 In fact most of São Paulo plants sell excess bagasse to other industries, mainly orange juice plants, located nearby. 7 Low pressure 1.5 bar, 215 o C (Copersucar, 1991)
4 operation hours: 3,190 h during harvesting season; 7,000 h when considering season and off-season. When the generation system works all over the year, excess bagasse from harvesting season is stored to be used off-season. In some cases, complementary bagasse is bought in off-season period. The base case configurations adopted Two different base cases are considered to evaluate electricity and steam generation costs for the current situation of the chosen plant: 1. Base case I : the alcohol plant still operates with the same original equipment 8, so investments in cogeneration plant have already been paid; evaluation of generation costs includes only bagasse opportunity cost, as well as the revenue from bagasse s sales (26.54 of produced bagasse). 2. Base case II (configuration 2.1, from Table 1): the alcohol plant must replace its original equipment, although with the same previous technology. No investments in energy conservation improvements are made in this case. The configurations adopted Tables 1 and 2 show proposed configurations with corresponding investments and surplus electricity production (Copersucar, 1991), based on a conventional Rankine cycle. Investments shown in Tables 1 and 2 include bagasse system and energy conservation improvements. In all cases, thermoeconomic analysis is based on the following cost rate balances (Bejan, Tsatsaronis, Moran, 1996): for boiler system: c hps * B hps = c bag *B bag + C bs for steam turbine: c e * W e + c lps * B lps = c hps + C st where: c hps = specific cost of high pressure steam, exergy basis; B hps = exergy rate of high pressure steam; c bag = specific bagasse opportunity cost, exergy basis; B bag = exergy rate of bagasse; C bs = capital cost for boiler system 9 ; c e = electricity generation cost; W e = generated power; c lps = specific cost of low pressure steam, exergy basis; B lps = exergy rate of low pressure steam; C st = capital cost of steam turbine and condenser (in CEST/CST cycles). 8 Boilers pressure equal to 21 bar, back pressure steam turbines; no surplus electricity. 9 Including bagasse system and investment on energy conservation improvements; this figure includes also the revenue from bagasse sales.
5
6 Configuration 2.1. New boiler (21 bar), new BPST 2.2. New boiler (21 bar), new BPST; energy conserv. improv New boiler (60 bar); new BPST (60/21 bar) 2.4. Same 2.3 config. with electric driven pumps 2.5. New boiler (80 bar); new BPST (80/21 bar) 2.6. Same 2.5 config.; total electrif Same 2.5 config. with electric driven pumps Investments US$/ kw 10 Energy consumption variation in alcohol plant () stea electricit m y , , , Surplus electric-ity. kwh/tc US$; investments were not updated taking into account US$ inflation because equipment s prices can be considered almost the same nowadays, when compared to 1990.
7 Table 2: Cogeneration systems with condensing extraction steam turbines (CEST) or condensing steam turbines (CST). (Copersucar, 1991) Description Investment Energy consumption variation in alcohol plant () Surplus electricity 11. US$/kW steam electricity kwh/tc 3.1. New boiler (21 bar); CST 1, , New boiler (60 bar); CEST 1, , Two new boilers (80 bar); one CEST; total electrification Two new boilers (80 bar); one CEST; electric driven pumps 3.5. Two new boilers (80 bar): one CEST; electric driven pumps 1, ,68 1, ,87 1, ,72 11 During harvesting season.
8 OBTAINED RESULTS Electricity and steam generation costs of the base case configurations are obtained considering that c e = c lps (equality method). The obtained results are: for base case I: US$ 9.06/MWh for base case II: US$ 18.15/MWh For each new proposed configuration, electricity costs are evaluated considering that the costs of low pressure steam are the same calculated for the base case configuration (method of electricity as by-product). Figures 1 and 2 show electricity costs in such conditions, with corresponding electricity surplus to be sold to the grid. Figure 1 presents results to back-pressure steam turbine configuration (BPST) and Fig. 2 corresponds to CST/CEST technology (condensing/extraction steam turbines). Electricity cost Configurations b.case I (US$/MWh) b.case II (US$/MWh) Exc. eletr.(kwh/tc) Fig. 1: Electricity costs from sugarcane origin in BPST systems Comparing results for season and off-season, it is observed an unexpected rise in electricity generation during season, despite the consumption of the plant. This is due to the fact that most proposed configurations maintain the existing BPST, operating in parallel with the new CEST system. These BPST system must stop during off-season, because there is no steam consumption in the plant. This fact explains also why electricity costs appear to be higher in off-season period. It can also be seen that some configurations are not economically interesting for
9 electricity generation, such as 2.4, 2.7, 3.5, 3.2, 2.1, where electricity surplus generation is lower than in the case of less expensive configurations. On the other hand, if the alcohol plant intends to keep its electricity costs equal to base case one, electricity sale s price will lead to significantly high values. Table 3 shows such results for CEST configurations, the most efficient ones among chosen technologies, for harvesting season. During off-season period, there is no energy consumption and all generated electricity is sold to the grid b.c.i&ii (US$/MWh)-off-seas. b.case I (US$/MWh)-season b.case II (US$/MWh)-season Exc eletr.(kwh/tc)-season Exc eletr.(kwh/tc)-off-seas Configurations Fig.2 Cogeneration in sugar cane industry from Table 3: Electricity sale s price during harvesting season for base cases I and II Electricity surplus sale s price (US$/MWh) Configurat Base case I Base case II On the other hand, comparing electricity generation costs to the official expansion marginal cost, US$38/MWh, it can be observed that in most cases generation costs are higher than marginal cost established by Eletrobrás. In this way, if only conventional mechanisms are employed to establish the purchase s price of electricity surplus from alcohol plant, there will be no agreement between the involved actors. There will be no interest from sugar/alcohol industries in exporting electricity. FINAL CONSIDERATIONS
10 Aiming to implement electricity generation from biomass origin, specially in sugar/alcohol plants, in order to lead to a large cogeneration biomass program, other mechanisms must be introduced to compare electricity generation costs. One of the existing proposals is the incorporation of environmental costs reflecting the advantages of using biomass-origin. In this case, further studies are necessary to compare environmental aspects of biomass-origin electricity to those from conventional generation systems (fossil fuel s origin or large hydroelectric dams), as previous studies have discussed preliminary (Coelho and Bolognini, 1996). Also, updating of Copersucar studies will be necessary to assure if investments assumed are still real or not. REFERENCES Bejan, A., Tsatsaronis, G., Moran, M. (1996). Thermal design and optimization. John Wiley & Sons, Inc., New York. Coelho, S. T. and Zylbersztajn, D. (1996). A preliminary analysis to improve electricity cogeneration from biomass origin in Brazil. In: Biomass (P. Chartier, G. L. Ferrero, U. M. Henius, S. Hultberg, J. Sachau, M. Wiinblad, ed.), Elsevier Science, Oxford. Coelho, S. T. and Bolognini, M. F. (1996). Incorporation of externalities as a mechanism to improve electricity cogeneration in Brazilian sugar/alcohol plants. In: III Conferencia de termoenergetica Industrial (proceedings). Las Villas (printing). Copersucar-Eletrobrás (1991). Geração de energia elétrica em usinas e destilarias-relatório técnico (in Portuguese), pp Copersucar, São Paulo. Eletrobrás (1996) Plano decenal de expansão (in Portuguese). Brasília. Macedo, I. C. (1997). Greenhouse gas emissions and bio-ethanol production/utilization in Brazil. Internal report CTC-05/97. pp Copersucar, São Paulo. Vertiola, S. R. and Oliveira Junior, S. (1996) Thermoeconomic analysis of the steam cycle of a Brazilian medium-sized sugar and alcohol mill. In: XI International symposium on alcohol fuels (proceedings), V.2, pp , Sun City, South Africa.
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