A Thermal Processing Plant in Thailand. A Case Study of Oil Palm Residues

Transcription

1 A Thermal Processing Plant in Thailand A Case Study of Oil Palm Residues

2 Case Study: Thermal Process Plant in Thailand START Technological Considerations Social-Cultural Considerations Environmental Considerations Economical Considerations END

3 Area and Production by Province Province Rayong Chonburi Prachuap Kiri Khan Chumphon Ranong Surat Thani Phangnga Krabi Trang Nakhon Si Thammarat Songkhla Satun Yala Narathiwat Others Whole Kingdom Harvested Area (Rai) 6,106 35,866 40, ,648 13, ,567 31, ,908 55,828 24,593 13,389 73, ,671 5,889 1,643,881 Production (Tons) 12,517 87,661 92, ,576 29,874 1,129,889 75,201 1,402, ,908 54,784 30, , ,008 11,279 4,001,376

4 Technical Considerations: Oil Palm START Main Intention How much energy can be generated From the substrate How much energy surplus is available (determination of auxiliary consumption) Surplus Input: Type of Substrates Tool: List of substrates Calorific Potential Production Input: Quantity Energy Demanded Residue RPR Availability Tool: Calculation Value of Energy (ktons) Factoravailable (MJ/kg) substrate quantity (TJ) Available quantity Empty of substrate that can ,500 Be secured in Bunches the long run (7-10 years) Input: Selection of 4,001 Fibre substrate ,237 Is the substrate primarily suitable for Tool: List of substrates Thermal Shell or biogas process (suitability for thermal 123 or biogas process) Tool: Estimation of power generation potential from substrate

5 Previous Use of Oil Palm Residues Empty Bunches Fiber Shell Fuel 3% 85.8% 58.8% Sold % Soil Cover 30.9% 0.5% - Animal Feed Donate 7.7% 0.3% - Left

6 Location South of Thailand (strong palm oil industry) based on using palm oil residues generated from the palm oil production process substrates are available for more then 7-10 years Palm oil residues using for combustion: - Empty fruit bunches -Fibres - Shells

7 Other Considerations: Surat Tani Province Selected Economic Characteristics of households by socio-economic class of Surat Tani Province Average household size Income receivers Average age of head Average household expenses (baht) Average household current income (baht) Per capita expenses (baht) Per capita current income (baht) Percentage of household with and without electricity Average rent or rental value (baht) Area and Distance from District to Surat Tani Province

8 Biomass Agricultural Residues Source: Biomass One-Stop Clearing House. Chapter 1 Biomass Fuels. Conversion of biomass to electricity and thermal energy Biomass Fuels

9 Technical Considerations Example scenario for thermal treatment Testing decision support system Following elements should by convert 1. Process description, Substrate input and energy output 2. Plant and machinery formation 3. Quantity and energy balance 4. Flow chart 5. Estimate of investment costs (Size of plant)

10 Location: Surat Thani, Krabi, & Nakorn Si Thammarat 82 km

11 General description Residues from factories 3 provinces: Surath Thani, Krabi and Nakhon Si Thammarat Location: Wiang Sa District Transport it to a central treatment plant conventional process specially designed water tube boiler to generate electricity by a steam turbine generator

12 Biomass Input Production 2002 (tons) Residue RPR Surplus Availability Factor tons (RPR*SAF*t) Calorific Value (MJ/kg) Potential Energy (TJ) Empty bunches (20 %H 2 O) (0.240 *0.584) Fibre (20 %H 2 O) Shell (12 %H 2 O)

13 Quantity balance per hour moisture ash C H O N S Cl Total Consisting palm oil residues (wet base) In % Total quantity in t/h EFB Fibre Shell EFB Fibre Shell Total

14 Combustion 8.4 t C t O t CO2 O 2 demand Air demand m t O2 density m kg/ m kg 89.7 t Air density 1.87 kg/m3 λ = 1. 3

15 Flow Chart Quantity base per hour Feed water Back pressure Heat exchanger Storag e 2 EFB 45 t Boiler (Stoker Fired) Steam Turbine G t Drying Steam Condenser Fuel prep (Shredder) Storag e 1 Shell/ Fibre 7 t Dryer t Grate ash 1.3 t Air heater Combust air vent t ESP Fly ash 0.4 t Moisture loss

16 Plant and machinery formation Machinery Storage buildings (The prepared material can be stored in a silo or underground store room) Shredder Ventilate drying with heated air Discharge screw or similar hoisting and conveying engineering s Under-stoker boiler Description Different constructions High weather protection, less working time demand for inand outputting Concussion demand Breaking the materials between the revolving tools and the hard ground -for preparing of mulch and compost substrates -robust against impurities Using waste air (By active processes mostly belt-, rotary- or flash dryers ) Material get into the combustion system by the moving of a screws, chains or braces - Biomass inputting directly with a discharge screw - With a stoker screw gets the substrate in the combustion chamber - Stoker-screw must be heat-proofed in the fired area - Self-activating, good regulating process - Low emission of pollutants - Self working process

17 Plant and machinery formation Water tube - Tubes contain water and the gases pass over these tubes, generating steam - Circulate boilers are usual for biomass combustion - More suited for large capacities Condensation steam turbine - Stream engines - The steam strikes to the rotor and initiate a movement and so mechanical energy - This energy is used for impelling the generator to produce power - For normal or high power output (>2 MW el.) (Currently the highest output is 850 MW el.) (Multi-) cyclone Other exhaust cleaning systems if it is necessary Flue gas goes tangential into the cyclone. Particles go down with the centrifugal forces. Electric filter, washer,

18 Energy balance per hour Heating Value (kj/kg) Mass in t EFB 15, Energy input in GJ/ h Fibre 15, Shell 16, Total in GJ/h Energy in GJ

19 Properties of superheated steam 40 bar/350 degree 3087 kj/kg 10 bar/ 180 degree 2778 kj/kg Difference 309 kj/kg Input Energy GJ/h Boiler eff GJ/h Production of steam t Turbine eff. 0.4 Generator eff Net electricity out GJ GJ MWel.

20 Flow Chart of Energy Balance per hour Feed water Energy based per h Steam after Turbine (10 bar, 180 degree) 2778 kj/kg Back pressure Heat exchanger Stor age 2 EFB Fuel preparat ion (Shredd er) Boiler efficientl y 70 % 110 GJ t Sto rag e 1 She ll/ Fibr 351 GJ Dryer Steam (40 bar, 350 degree) 3087 kj/kg t/h Boiler (Stoker Fired) eair heater Combus tion air ventilati on t Steam Turbine efficiently 40% ESP Fly ash 0.4 t Stac k 34 MW el. G GJ t Drying Steam Conden er

21 Purchased equipment Equipment 1 Fuel Preparation (Shredder) 2 Dryer 3 Boiler 4 Boiler feed water/deaerator 5 Steam turbine/generator 6 Cooling water system Total Machinery 7 Baghouse & Cooling Tower 8 Plant Control Syst.&Inf. 9 Water Treat. Plant 10 Laboratory Equipment 11 Workshop Equipment Total Purchased Equipment Cost per kw (US $) Total Cost for kw ,476, ,301,935

22 Estimated Investment Costs 1 Purchased equipment 22,301,935 2 Piping Electrical works Instrumentation Utilities Foundation Insulation Painting, fire protection, safety, miscellaneous Yard improvement Environmental control Building Land Standby Gen-set for start-up Grid inter-connection Engineering services Contractors fee Contingency Offsite facilities Start up cost Working capital Total investment in US $ 55,507,138

23 Operating Costs Components 1 Raw materials 2 Utilities 3 Operating labor 4 Labor related cost 5 Consumables 6 Operating supplies 7 Local taxes, insurance 8 Research & Development 9 Adaptation levy and administrative expenses Total operating costs 10 Maintenance Annual O & M expenses Cost (USD) ,039, ,704,276

24 Specific energy costs 34,080 kw Electricity 8,000 h Hours per year 272,640,000 kwh Electricity per year 4,704,276 $/year Operating Costs $/kwh 0.69 Baht/kWh 1$ = 40 Baht Electricity Price: Peak hour (9:00-22:00 and all day Sunday): baht Off peak hours: baht

25 Electricity Transmission Network

26 Economic Characteristics of Household Surat Thani Province % distribution All household 100 Farm Operators 33.2 Own- Account, non-farm 17.6 Employees 41.5 Economically inactive 7.7 Avg income (baht) 11,855 11,111 13,521 12,724 6,589 Avg size With Electricity Total Population: 867,388 (M430,479; F436,909)

27 EPPO Master Plan for the Promotion of Renewable Energy Request for proposal (43 proposals; 775 MW) Preliminary evaluation on technical feasibility, financial, etc. (31 projects approved, MW) Public consultation hearing 10 km radius Community participation EIA Monitor and evaluation Three party committee Government agent, community representative, and plant owner Environmental and Social Impact Assessment 20 projects approved; MW; 1400 million baht support

28 List of Thermal Plants Owner/developer A.T. Biopower Co, Ltd Patum Rice Mill and Granary Public. Co. Ltd. Mitr Phol Sugar Corp., Ltd. Electricity Generating Public Co., Ltd. Laem Chabang Industry Co., Ltd.* Industry Project developer Rice Sugar Wood Wood Location Central Thailand Pathumtani, Thailand Supahanburi, Thailand Yala, Thailand Laem Chabang, Chonburi, Thailand Areechai Woodtech Co. Ltd.* Wood Srakaew, Thailand High Tech Paper Co. Ltd.* Paper Panom Sarakham, Chachoengsao, Thailand Chia Meng Co. Ltd.* Rice Nakorn Ratchasima, Thailand TRT Parawood Co. Ltd.* Wood Surat Thani, Thailand The Southern Palm (1978) Co., Ltd. Palm Oil Surathani, Thailand

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31 Energy situation Palm oil mills Old cogeneration plants (20 to 50 years) with low pressure boilers and less efficient turbines Not possible to sell electricity in the past Seasonal operation using only fibre and shell Emerging trend Need to replace old cogeneration system Good potential for high pressure boilers and efficient turbines Excess power exported to grid Use of empty fruit bunches, fibre and shell Plant operation throughout the year Already few palm oil mills started implementing efficient cogeneration systems 1 tonne of fresh fruit bunches Process energy required: kwh/t 0.73 tonne of steam 200 kg palm oil Waste: kg POME ~ 20 m 3 biogas 190 kg fibers + shells 230 kg empty fruit bunches

32 Nakhonpathom Province 1 million pigs : 5,400 farms 1,700 factories serious water pollution

33 The distribution of pig density in district level