Möglichkeiten der Reststoffnutzung in der Zuckerindustrie: Filterkuchen und Bagasse als Energieträger

Transcription

1 PEP-Informationsveranstaltung Energie aus Biomasse und Biogas 12. Februar 2014 Berlin Möglichkeiten der Reststoffnutzung in der Zuckerindustrie: Filterkuchen und Bagasse als Energieträger Dipl.-Ing. Werner Siemers Thermische Prozesstechnik

2 Introduction Table of content Overview on the sugar industry in The Philippines Prospects for cogeneration Prospects for biogas production Background information CUTEC as applied research institute 100 employees 5 Departments Energy System Analysis Metal Recycling Wastewater Process Engineering Chemical Energy Systems Thermal Process Technology 2

3 Sugar industry in the Philippines General information Production: 23,880,000 TC, 29 sugar mills Feed-in law exists Bioethanol mandate exists Milling season: 6 months, November to April Some mills have already plans for Cogeneration 30 MW, 34 MW (46 MW), 7 MW (12 MW), 4 to 9 MW etc. Spot market only: 4 to 5 PHP /kwh (10 to 12.5 ct/kwh) Steam consumption: 500 kg/tc ½ day maintenance (Sunday) Productivity: 55 TC/ha, sometimes 100 or 120 TC/ha Bagasse price: 45 to 50 /t 3

4 Sugar industry in the Philippines General information 4

5 Site visits La Carlota Interview results Carlota Calculations capacity Capacity ,00 TCpd 666,67 TCph Production ,00 TC/year Bagasse on cane 31,00 % 206,67 t bagasse per hour Moisture bagasse 52,00 % Steam on bagasse 1,90 t steam / t Bagasse 1,69 t steam / t Bagasse Total steam 350,00 tph specific steam 0,51 t/tc 0,53 t steam/tc Boilers 200,00 tph 450,00 psi 120,00 tph 400,00 psi 140,00 tph 250,00 psi Power output 12,00 MW 18,00 kwh/tc Power demand 12,00 MW 18,00 kwh/tc Export Power 0,00 MW 0,00 kwh/tc Import Power 0,00 MW 0,00 kwh/tc Turbines 6,00 MW 400,00 psi 5,00 MW 250,00 psi 7,50 MW 150,00 psi Filter mud on cane 5,00 % 800,00 t Filter mud per day Sugar rest 1,50 pol% 5

6 Site visits Lopez Interview results Lopez Calculations Sugar Refinery Capacity 7.200,00 TCpd 300,00 TCph Production ,00 TC/year Bagasse on cane 31,00 % 93,00 t bagasse per hour Moisture bagasse 51,00 % Steam on bagasse 2,10 t steam / t Bagasse 1,92 t steam / t Bagasse Total steam 179,00 tph specific steam 0,54 t/tc 0,60 t steam/tc 0,1 t steam Boilers 100,00 tph 400,00 psi 100,00 tph 250,00 psi Power output 7,00 MW 23,33 kwh/tc 3 MW Power demand 8,40 MW 28,00 kwh/tc Export Power 0,00 MW 0,00 kwh/tc Import Power 1,40 MW 4,67 kwh/tc Turbines 10,00 MW 400,00 psi 4,70 MW 250,00 psi 3,50 MW 150,00 psi Filter mud on cane 3,00 % 216,00 t Filter mud per day Sugar rest 3,00 pol% 6

7 Site visits Tarlac Interview results Tarlac Calculations Capacity 7.000,00 TCpd 291,67 TCph Production ,00 TC/year Bagasse on cane 29,00 % 84,58 t bagasse per hour Moisture bagasse 51,50 % Steam on bagasse 2,20 t steam / t Bagasse 2,03 t steam / t Bagasse Total steam 172,00 tph specific steam 0,57 t/tc 0,59 t steam/tc Boilers 140,00 tph 250,00 psi 45,00 tph 250,00 psi Power output 5,90 MW 20,23 kwh/tc Power demand 7,40 MW 25,37 kwh/tc Export Power 0,00 MW 0,00 kwh/tc Import Power 1,50 MW 5,14 kwh/tc Turbines 3,50 MW 150,00 psi 6,00 MW 250,00 psi Filter mud on cane 2,60 % 182,00 t Filter mud per day Sugar rest 3,50 pol% 7

8 Site visits First Farmers, already equipped with Cogeneration Interview results First Farmers Calculations Capacity 4.500,00 TCpd 187,50 TCph Production ,00 TC/year Bagasse on cane 30,00 % 56,25 t bagasse per hour Moisture bagasse 50,00 % Steam on bagasse 2,30 t steam / t Bagasse 2,15 t steam / t Bagasse Total steam 120,70 tph specific steam 0,53 t/tc 0,64 t steam/tc Boilers 180,00 tph 850,00 psi for mill 106,60 tph 0,57 t steam/tc 160 and 15 psi Power output 11,49 MW 61,28 kwh/tc Power demand 4,29 MW 22,88 kwh/tc Export Power 7,20 MW 38,40 kwh/tc Import Power 0,00 MW 0,00 kwh/tc Turbines 18,00 MW 850,00 psi Filter mud on cane 3,00 % 135,00 t Filter mud per day 8

9 Results of mission Technical parameters Model calculation based on technology steps National potential between 500 and 1,000 MW Individual mills 20 MW to 100 MW Export potential 40 to 100 kwh/tc Description Unit Carlota Lopez Tarlac Philippines Milling/Production TC/y Installed Capacity MW base case, 20 bar 33,70 15,20 13,70 376,20 increased pressure, 40 bar 49,60 22,30 20,20 553,63 high pressure, 70 bar 82,60 37,20 33,70 922,98 higher pressure, 100 bar 89,10 40,10 36,20 993,87 Export electricity kwh/tc base case, 20 bar 6,00 n.a. n.a. increased pressure, 40 bar 42,65 41,38 36,41 40,15 high pressure, 70 bar 89,65 89,96 82,35 87,32 higher pressure, 100 bar 103,69 103,48 94,48 100,55 9

10 Results of mission Economic analysis Model calculation using standard procedures Shown as one example (upper limit) Description Unit Carlota Lopez Tarlac Production cost ct/kwh base case, 20 bar 38,40 n.a. n.a. increased pressure, 40 bar 16,76 11,64 20,16 high pressure, 70 bar 16,77 11,12 18,44 higher pressure, 100 bar 15,40 10,26 17,15 IRR % base case, 20 bar -1,32 n.a. n.a. increased pressure, 40 bar 11,51 20,30 7,70 high pressure, 70 bar 11,55 21,00 9,71 higher pressure, 100 bar 13,27 23,06 11,11 Additional Biomass* Production cost ct/kwh base case, 20 bar 18,93 25,02 23,11 increased pressure, 40 bar 13,21 11,67 13,82 high pressure, 70 bar 10,43 9,24 10,59 higher pressure, 100 bar 10,23 8,89 10,50 * for h/y and 50 USD/t 10

11 Results of mission Economic analysis Important are the production cost for the export unit of electricity <<<<<< Feed-in Tariff (16.5 ct/kwh) or export price on spot market(10.0 to 12.5 ct/kwh) IRR depends on the selected financial conditions Additional biomass can prolong the plant usage Even with 50 /t the production costs are lower and are below the FIT 11

12 Filter mud in sugar industry Data Moisture content 70% to 80% Ash according to practise and agriculture Volatile solids, organic dry matter Flocculants, lime according to processing Besides plant material (lignin, hemicellulose and cellulose) it contains sugar, wax, proteins Limited literature available, for example Protein 5% to 15% DM Sugars 5% to 15% DM Fibres 12% to 20% DM Ash 9% to 20% DM 12

13 Filter mud in sugar industry Problems High solids content already Fine particles High fibre content Sugars decompose quickly Biogas needs continuous system, sugar is only seasonal 13

14 Biogas from filter mud Solution Dry fermentation Low permeability of substrate Percolation of the liquids? Landfill system prolonged retention time, 6 months, biogas from decomposition CSTR (complete stirred tank reactor) Mix with distillery waste water (vinasse with 120,000 to 150,000 mg/l BOD) and/or wastewater from sugar mill (4,000 to 6,000 mg/l BOD) One sugar mill gives good results, 5% DM Another mill results in 12% DM 14

15 Biogas from filter mud Yield overview DBFZ Kenya 53 to 80 m 3 Biogas per t fresh material Thailand, trials 30 m 3 Biogas per t fresh material USA, model calculation 68 m 3 Biogas per t fresh material Proposed plant in India by Biogas Nord (?) 15

16 Biogas from filter mud Potential in the Philippines Potential nationwide on conservative estimations 13 MW to 53 MW electrical capacity Individual sugar mills depending on size 300 kw to 5 MW Description Unit Carlota Lopez Tarlac Philippines Filter mud % 5,00 3,00 2,60 3,75 Milling capacity TC/d , , , ,00 Amount of filter mud t/d at 20 m3 Biogas/t fresh MW** at 80 m3 Biogas/t fresh MW** **with Biogas 6 kwh/m3 and electrical efficiency of 35% 16

17 Conclusion From the analysis Cogeneration might be financially viable Process parameters favour higher system pressures with higher export potential Additional biomass material is necessary Tops and trash Rice residues Energy plantations Problem for biomass material is generally the logistical challenge Biogas from filter mud shows lower potential Technical solution is not ready available yet 17

18 Conclusion For the German industry Biomass Powerplants or parts thereof Engineering and components Service and maintenance Solutions for logistics in biomass material Baling, transport, disintegration, pelletizing, briquetting Solution for biogas plants using filter mud and other wastewater sources Technical specifications still to be developed 18

19 Thank you very much for your attention Contacts Werner Siemers c/o CUTEC Institut GmbH 19