Sugar Cogeneration in Thailand

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1 Emerging Trends in Sugar Mill Cogeneration Training on and transfer of efficient EU technologies in the sugar sector in Thailand (SPF- Sugar) Arul Joe Mathias Biomass and CDM expert 6-8 September 2006 Arnoma Hotel, Bangkok, Thailand. 1 Sustainable Environment through Clean and Efficient Energy Projects Sugar Cogeneration in Thailand Mostly low pressure boilers Some are very old (over 30 years) Inefficient cogeneration plants. Boilers have been designed deliberately with low efficiency. Purchase of used equipments from western countries are common. Cogeneration within the same company 2 Sustainable Environment through Clean and Efficient Energy Projects

2 Developments in the past few years Use of medium pressure boilers (over 30 bar) Excess electricity export to the national grid. Use of alternative biomass fuels (rice husk, bark, other wood waste etc.) Several mills are studying the possibilities to upgrade/implement new projects 3 Sustainable Environment through Clean and Efficient Energy Projects Developments in the past few years Professional approach in project development. Systematic feasibility studies and Implementation Tendering Negotiation Contract management Use of special purpose company 4 Sustainable Environment through Clean and Efficient Energy Projects

3 Energy requirement and supply in the sugar industry Process energy required: Electricity: kwh/t of sugarcane 0.4 tonne of steam 1 tonne of Sugarcane kg Sugar Waste: 290 kg Bagasse ~ 100 kwh electricity 5 Sustainable Environment through Clean and Efficient Energy Projects Power generation potential (partly utilised) in ASEAN Country Sugar cane production (1,000 tonnes) Bagasse production (1,000 tonnes) Max. Power Generation Potential (GWh/year) Indonesia 31,000 8,990 2,997 Philippines 21,000 6,090 2,030 Thailand 54,000 15,660 5,220 Vietnam 12,000 3,480 1,160 Total 118,000 34,220 11,407 Bagasse = Sugar cane * 0.29; 1 kwh = 3 kg of bagasse (including steam for process) 6 Sustainable Environment through Clean and Efficient Energy Projects

4 Role of European Technology in Thailand s Sugar Cogeneration A project implemented in Danchang Bioenergy, Thailand with European technology set a new benchmark for sugar cogeneration in Thailand 7 Sustainable Environment through Clean and Efficient Energy Projects Dan Chang Bio Energy Owner/Developer : Mitr Phol Sugar Corporation Limited Size Location : 27,000 TCD (2.25 million TCY) : Dan Chang, Suphanburi province Existing equipment : Consisting of several old boilers and turbines New boilers Grate type New turbine : 2 x 120 tph, 68 bar, C : Water cooled vibrating grate : Extraction condensing turbine (41 MW gross) 8 Sustainable Environment through Clean and Efficient Energy Projects

5 Fuel Dan Chang Bio Energy : Bagasse, cane leaves, wood bark and rice husk Off-taker : Electricity Generation Authority of Thailand (EGAT) Electricity export to EGAT : 25 MW Export tariff : 2.14 Baht/kWh (grid); 1.85 Baht/kWh (sugar mill) Management Supplier : Special Purpose Company : ALSTOM Contract type : Fixed price, fixed time turnkey with LD 9 Sustainable Environment through Clean and Efficient Energy Projects 10 Sustainable Environment through Clean and Efficient Energy Projects

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7 13 Sustainable Environment through Clean and Efficient Energy Projects Major Technical Attractions First high pressure boiler in ASEAN sugar industry Boiler efficiency above 90 % (LHV basis) First high pressure turbo-generator system Turbine efficiency around 85 % (design) Cogeneration efficiency above 70 % Optimized plant design High flexibility in operation Consistent electricity export: above 25 MW 14 Sustainable Environment through Clean and Efficient Energy Projects

8 Major Technical Attractions Multi-fuel firing capability Water cooled vibrating grate furnace Modern control system (DCS), monitoring Use of steam transformers No delay in construction and operation Plant met the performance guarantee figures agreed in the contract Excellent workmanship 15 Sustainable Environment through Clean and Efficient Energy Projects 16 Sustainable Environment through Clean and Efficient Energy Projects

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12 ATM 5 bar HDR Main Steam from Boiler2 HP Turbine Gear lube oil LubeOil unit Gen. ex Pegging Steam to St.coil A/H Deaerator GEN.cooler LP Turbine BFP-1 BFP-2 BFP-3 P-1-- Condenser BlowDown Flush ATM Condensate P1 Condensate P2 Feeder air fan Eco. Boiler12 BlowDown Tank Service W. Gland ST Cond. Submerge Ash conveyer Secondary air fan Steam Transformer 2x100% Aux.cooling Pump Sampling SA.Fan Vacuum cooler bearing pump Spare cooler Spare Make Up water Sulphuric Acid dosing Sodium 2x50% Hypochlorite CW.Pump dosing Mechanical Department Dan Chang Bio Energy Thermal Power Plant Construction Project Division(EGAT) Process diagram 23 Sustainable Environment through Clean SIZE FSCM DWG.by Chatchawan B and NO Efficient Energy DWG NO Projects REV Issue 19/9/2003 SCALE 1 : 1 SHEET 1 OF 1 Environmental Management No black smoke during the boiler operation. Efficient wet scrubber system to control the particulate emission Clean bottom ash collection system (wet) Clean fly ash collection system (wet) Proper ash disposal (used as fertiliser in the sugar plantation land sites) 24 Sustainable Environment through Clean and Efficient Energy Projects

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15 Environmental Performance CO 2 mitigation potential : 80,000 ton CO 2 /year Particulate emission within Thai limitations Stack emission CO ppm NO x ppm SO ppm 29 Sustainable Environment through Clean and Efficient Energy Projects Sugar Cogeneration: Future trend Several sugar mills expected to implement high pressure system Old plants are expected to be replaced by new projects Year round operation of the cogen plant expected Boilers will be designed for multi-fuels Potential to implement more than 20 high pressure systems in Thailand Confidence level in the industry will drive even higher pressure systems (close to 100 bar) 30 Sustainable Environment through Clean and Efficient Energy Projects

16 For more information, please contact: Thank You! 31 Sustainable Environment through Clean and Efficient Energy Projects