ASEAN Market for Cogeneration and Business Opportunities

Transcription

1 ASEAN Market for Cogeneration and Business Opportunities 25 February 2004 Hilton City Hotel Brussels, Belgium Eric Chanfreau 1

2 ASEAN Market for Cogeneration and Business Opportunities Presentation Outline 1. What is COGEN 3? 2. Full Scale Demonstration Projects New Cogeneration Projects 4. Emerging trends and Case studies 5. Financing Power Projects in ASEAN 6. Conclusions 2

3 (COGEN 3) An economic cooperation programme between: European Commission (EC) & Association of South East Asian Nations (ASEAN) Funded by the EC (25 M EUR) Implementation: Jan 2002 Dec 2004 Coordinated by Asian Institute of Technology (AIT) & Carl Bro International AB 3

4 COGEN 3 Objectives Promote the use of Cogeneration in ASEAN Promote proven, clean and efficient European Cogeneration technology Create business opportunities for cogeneration within the ASEAN industrial sectors using Biomass, Coal and Gas as fuels 4

5 Stakeholders European Equipment suppliers European developers, banks and financiers ASEAN cogeneration project developers ASEAN suppliers ASEAN banks and financiers ASEAN policy makers 5

6 COGEN 3 Organisation Clients in Europe Clients in ASEAN COGEN 3 European Office (5) Malmö, Sweden COGEN 3 Programme Management Unit (22) Bangkok, Thailand COGEN 3 ASEAN Country Coordinators: 7 Countries (24) 6

7 COGEN 3 Country Co-ordinators ordinators The Research Center for Energy and Environment, Hanoi The Energy Conservation Center of Thailand, Bangkok Energy Development and Utilization Foundation, Manila Ta Prohm Consultants, Phnom Penh SIRIM, Shah Alam Energy Ventures, Singapore Research and Development Center for Energy and Electricity Technology, Jakarta 7

8 Support to Cogeneration Project Development Technology selection and Business Facilitation Feasibility studies (Techno-Financial Analysis) Tools for development, assessment and implementation of cogeneration projects Full Scale Demonstration Projects Financial packaging Supplier Matchmaking 8

9 Technical, Business and Market Information Directories on European and ASEAN equipment suppliers and service providers Report on Cogeneration Technologies Cogeneration Project Development Guide Sectoral Report on Energy Intensive Industries National Cogeneration Policy Reports 9

10 Training Seminars, Workshops, and Study Tours, focused on: Technical issues Policy issues Financial issues Environmental issues 10

11 ASEAN Market for Cogeneration and Business Opportunities Presentation Outline 1. What is COGEN 3? 2. Full Scale Demonstration Projects New Cogeneration Projects 4. Emerging trends and Case studies 5. Financing Power Projects in ASEAN 6. Conclusions 11

12 Full Scale Demonstration Projects The implementation of proven cogeneration technology in a full scale project, in order to demonstrate its technical reliability and economic viability. An FSDP is a showcase in ASEAN aiming to convince other potential end-users to select European cogeneration technology. 12

13 Support to Cogeneration Projects and Full Scale Demonstration Projects (FSDPs) Active facilitation among stakeholders of cogeneration projects Financial packaging, networking and fund mobilisation Selected projects (FSDP) will get support with investment, training and monitoring 13

14 FSDP Eligibility Criteria Cogeneration Implemented in ASEAN European equipment Proven technology Biomass, coal and/or gas as fuels Compliance with national regulation Implemented before December

15 Support to FSDP 15% of eligible equipment cost Ceiling at 400,000 Euro Support for training, monitoring and advertising 15

16 24 Selected FSDP Candidates Capacity: MW (Total: MW) Total Amount of EC support: 6,835,853 EUR Total Eligible Cost: 91,996,344 EUR Total Investment: 208,841,000 EUR 16

17 5 projects in Thailand Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration 1 project in Vietnam 1 project in Cambodia 1 project in Philippines 8 projects in Malaysia 2 projects in Singapore 17 6 projects in Indonesia

18 Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration Palm oil waste: 8 Rice husk : 6 Bagasse : 2 Wood waste : 3 Biogas : 4 * Bio-oil : 1 18

19 ASEAN Market for Cogeneration and Business Opportunities Presentation Outline 1. What is COGEN 3? 2. Full Scale Demonstration Projects New Cogeneration Projects 4. Emerging trends and Case studies 5. Financing Power Projects in ASEAN 6. Conclusions 19

20 Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration 145 New Cogeneration Projects in South East ASIA Developing Cogeneration Projects by Sector Sector Country No. of Capacity CB ID MY PH SG TH VN Projects (MW) Cement Chemical Food* Land field&waste Palm oil Power&Utilities** Pulp&Paper Rice Sugar Textile Unspecified Wood Note: * Including Fruit, Cassava & starch, Tea, Farm, Livestock, Piggery and Tannery ** Including Airport, Army, Commercial complex, IPP and SPP 20

21 ASEAN Cogeneration Project Potential No. of project (s) Cement Chemical Food* Land field&waste Palm oil Power&Utilities** Pulp&Paper Rice Sugar Textile Unspecified Wood 0 Sector 21

22 ASEAN Cogeneration Project Potential MW Cement Chemical Food* Land field&waste Palm oil Power&Utilities** Pulp&Paper Rice Sugar Textile Unspecified Wood Sector 22

23 ASEAN Market for Cogeneration and Business Opportunities Presentation Outline 1. What is COGEN 3? 2. Full Scale Demonstration Projects New Cogeneration Projects 4. Emerging trends and Case studies 5. Financing Power Projects in ASEAN 6. Conclusions 23

24 Emerging trend in biomass power generation/cogeneration Sugar industries shift from low pressure into high pressure system + electricity export Palm oil industries - shift from low pressure into high pressure system + electricity export Rice industries new medium pressure and high pressure system Wood industries new medium pressure and high pressure system High pressure system with mixed fuel firing 24

25 Sugar mills: Energy situation Old cogeneration plants (20 to 50 years) Low pressure boilers 20 to 30 bar and less efficient back pressure turbine Not possible to sell electricity in the past Seasonal operation using only bagasse Process energy required: kwh/tonne of sugarcane 0.4 tonne of steam 1 tonne of sugarcane kg sugar 25 Waste: 290 kg Bagasse ~ 100 kwh

26 Sugar mills: Emerging trend Need to replace old cogeneration system Good potential for high pressure (over 60 bar, C) boilers and efficient extraction condensing turbines Excess power exported into grid Use of multi-fuel boilers Plant operation throughout the year Already few sugar mills started implementing high pressure boilers and efficient turbo generator systems 26

27 Location Thailand, Vietnam, Philippines, Indonesia Sector Sugar Mill capacity 5,000 20,000 tonnes per day Size of project 5 50 MW Technology High pressure steam boiler (> 40bar) + extraction condensing steam turbine Fuel Bagasse Investment cost 1,000 1,500 EUR/kW Ownership structure Corporation / professionally managed Other information Other biomass fuels (rice husk and wood wastes) may be used as secondary fuels Excess power to be sold to the grid 27

28 Sugar industries: Fuel availability and cogeneration potential 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) 28

29 Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration Emerging trend in sugar mill cogeneration: Dan Chang Bio Energy Project Owner/Developer : Mitr Phol Sugar Corporation Limited Industry Size Location : Sugar : 27,000 TCD (2.25 million TCY) : Dan Chang, Suphanburi province Existing equipment : Consisting of several old boilers and turbines New boilers New turbine : 2 x 120 tph, 68 bar, C : Extraction condensing turbine (41 MW gross) 29

30 Fuel Project status Off-taker Electricity export to EGAT Emerging trend in sugar mill cogeneration: Dan Chang Bio Energy Project Export tariff Management : Bagasse, cane leaves, wood bark and rice husk : Commercial operation is expected in March 2004 : Electricity Generation Authority of Thailand (EGAT) : 25 MW during peak hours 16 MW during off-peak hours : 2.14 Baht/kWh (grid); 1.85 Baht/kWh (sugar mill) : Special Purpose Company 30

31 Palm oil mills: Energy situation Old cogeneration plants (20 to 50 years) Low pressure boilers 20 to 30 bar and less efficient back pressure turbine Not possible to sell electricity in the past Seasonal operation using only fibre and shell 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 31

32 Palm oil mills: Emerging trend Need to replace old cogeneration system Good potential for high pressure (over 30 bar, C) boilers and efficient extraction condensing turbines Excess power exported into grid Use of empty fruit bunches, fibre and shell Plant operation throughout the year Already few palm oil mills started implementing high pressure boilers and efficient turbo generator systems 32

33 Palm oil industries: Fuel availability and cogeneration potential Country FFB production (1,000 tonnes) Residue production (1,000 tonnes) Max.Power Generation Potential (GWh/year) Indonesia 25,000 10,500 4,200 Malaysia 42,000 17,640 7,056 Philippines Thailand 2, Total 69,600 29,232 11,693 Residue = Fresh Fruit Bunch * 0.42; 1 kwh = 2.5 kg of residues (including steam for process) 33

34 Location Sector Mill capacity Size of project Malaysia, Indonesia Palm oil t FFB/h 1 20 MW Technology High pressure boiler (>40 bar) + Extracting condensing steam turbine Fuel Investment cost Ownership structure Other information EFB is a new fuel Palm oil wastes (Empty Fruit Bunches (EFB), fibres, shells, ) 1,000 1,500 EUR/kW Excess power to be sold to the grid Corporation / family owned 34

35 Emerging trend in palm oil mill cogeneration: TSH Bio-Energy Owner : TSH Bio Energy Sdn Bhd Location : Kunak, Sabah Size : ,000 MT/yr Capacity : 14 MW Boiler : 80 tph, 70 bar at design and 58 bar at actual, 402 deg C Supplier : Babcock & Wilcox Volund Fuel : EFB, mesocarp fiber and palm kernel shell Electricity : Sales to Sabah Electricity Sdn Bhd 35

36 Rice mills: Energy situation Only few plants implemented so far Revenue from ash sales (50 to 100 USD/ton) Rice husk is also fired with wood waste and bagasse Dumping or open burning is also common Process energy required: Paddy milling and drying: kwh/tonne paddy 1 tonne of paddy kg white rice Waste: 220 kg husks ~ 150 kwh 36

37 Rice mills: Emerging trend Good potential for high pressure (over 30 bar, 3600C) boilers and efficient extraction condensing turbines Good potential to generate excess power to export to grid Separate isolated plants generating only power is also popular 37

38 Typical Characteristics Capacity Size of energy plant Technology Investment cost Ownership structure MW Rice 200-1,000 tonnes paddy/day Boiler + Steam Turbine 1,200-2,000 Euro/kW Family owned and managed 38

39 Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration Rice industries: Fuel availability and cogeneration potential Country Paddy production (1,000 tonnes) Rice husk production (1,000 tonnes) Max. Power Generation Potential (GWh/year) Indonesia 51,000 11,220 7,480 Malaysia 2, Philippines 11,000 2,420 1,613 Thailand 22,000 4,840 3,227 Vietnam 28,000 6,160 4,107 Total 114,000 25,080 16,720 Rice husk = Paddy * 0.22; 1 kwh = 1.5 kg of rice husk (including steam for process) 39

40 Chia Meng Rice husk plant in Thailand 2.5 MW Steam turbine Boiler: Reciprocating inclined grate type. Capacity 17 tph, 35 bar, 420 o C In operation since 1997 (COGEN phase 2 Full Scale Demonstration Project) Steam used for drying of rice paddy By-product: Ash sold to steel industries

41 Case 1: Gas Cogeneration in the Kuala Lumpur International Airport (1) 40 MW cogeneration Chilled water 30,000 RT Natural gas or Jet A1 Operation since

42 Case 1: Gas Cogeneration in the Kuala Lumpur International Airport (2) Configuration Gas Turbine Generator 20 MW x 2 units Heat Recovery Steam Generator 40 tph x 2 units Auxiliary Gas Boiler 25 tph x 2 units 40 tph x 1 unit Steam Absorption Chiller 30,000 RT (2,500 RT x 12 units) 42

43 Petronas Tower (452 m) Case 2: Gas Cogeneration in Petronas Tower, Kuala Lumpur (1) 25.8 MW cogeneration Chilled water 30,000 RT Natural gas Operation since

44 Case 2: Gas Cogeneration in Petronas Tower, Kuala Lumpur (2) Configuration Gas Turbine Generator 4.2 MW x 2 units 8.7 MW x 2 units Heat Recovery Steam Generator 10.7 tph x 2 units 18.7 tph x 2 units Auxiliary Gas Boiler 47 tph x 2 units Electrical Centrifugal Chiller 15,000 RT (5,000 RT x 3 units) Steam Turbine Centrifugal Chiller 15,000 RT (5,000 RT x 3 units) 4 km chilled water network of pipes 44

45 Case 3: Cogeneration in an Industrial Estate (1) 514 MW electricity 6 x 35 MW gas turbines 2 x 152 MW steam turbines 2 x Circulating Fluidised Bed Boilers 4 x Heat Recovery Units Primary fuels: Natural gas Indonesian bituminous coal Back up fuel: Diesel oil In operation since 2000 Supplies: Electricity, steam (200 tph) and demineralised water (150 m3/h) to industrial estate and the plant Electricity to grid

46 Case 3: Cogeneration in an Industrial Estate (2) One of the largest Cogeneration investments in Southeast Asia Base-load power to state utility Electricity Generating Authority of Thailand (EGAT) under a 25-year Power Purchase Agreement (PPA) PPA provides EGAT with secure power at a reasonable price Provides the sponsors with a secure return on investment 46

47 Case 4: Gas Industrial Cogeneration Thailand (1) Engine with Generator 47

48 Case 4: Gas Industrial Cogeneration Thailand (2) Cogeneration Flow Diagram Absorption Ch iller Gas-fired Boiler 48

49 Case 4: Gas Industrial Cogeneration Thailand (3) Gas engine generator 3 x 2000 kw Waste heat boiler 3 x 1.6 tons(steam)/hour Absorption chiller 3 x 360 tons(rt) 49

50 Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration Case 4: Gas Industrial Cogeneration Thailand (4) Waste Heat Boiler 50

51 Case 4: Gas Industrial Cogeneration Thailand (5) Absorption Chiller Flow Diagram 360 RT ABSORPTION CHILLER #1 360 RT STEAM ABSORPTION CHILLER #2 O 6-8 BAR 7 C 360 RT ABSORPTION CHILLER #3 CHILLED WATER 51

52 Case 4: Gas Industrial Cogeneration (Thailand) (6) Absorption Chiller 52

53 Case 5: Micro-turbine in a Rubber Gloves Industry Malaysia (1) 53

54 Case 5: Micro-turbine in a Rubber Gloves Industry Malaysia (2) Implemented in 2002 Bowman micro-turbine Implemented by Novalogics Integrated Sdn. Bhd. 80 kw electricity Hot water up to 80 C for leaching process 54

55 ASEAN Market for Cogeneration and Business Opportunities Presentation Outline 1. What is COGEN 3? 2. Full Scale Demonstration Projects New Cogeneration Projects 4. Emerging trends and Case studies 5. Financing Power Projects in ASEAN 6. Conclusions 55

56 Cogeneration Project Development Issues Commercial Viability: Does it make sense? Cogeneration Policy: Incentives? Financing: Can be difficult 56

57 Financing Power Projects in ASEAN Financing Power Projects after 1997 Trends and Outlook: Two pictures Overcapacity on national level Shelved projects queuing for implementation ESI Deregulation, Privatisation and merchant power Very few Large Power Projects under Development 57

58 Financing Power Projects in ASEAN Financing Power Projects after 1997 Trends and Outlook Continued Power Demand is increasing Local shortage of Power Increasing trend of projects being implemented with local sponsors, lenders and even technology Commercial and economic viability, not just project contracts 58

59 Financing Power Projects in ASEAN Financing Trends and Outlook Project Finance vs. On-Balance sheet - Project Finance (non/limited-recourse) Larger gas and coal projects (> 20 MW) - Project Finance (full sponsor guarantee) Larger biomass (> 10 MW) - On-Balance Sheet Smaller projects (< 10 MW) 59

60 Completion guarantee Risk management Construction / performance guarantee Operational / performance guarantee Financial guarantee PROJECT SPONSOR CONSTRUCTION CONTRACTOR OPERATION AND MAINTENANCE CONTRACTOR FINANCIAL INSTITUTION Performance guarantee EQUIPMENT SUPPLIER INSURANCE COMPANY Insurance protection PROJECT COMPANY Price / supply guarantee FUEL / RAW MATERIAL SUPPLIER LAW FIRM Security in contracts GOVERNMENT SURROUNDING PUBLIC PROJECT CONSULTANTS POWER / STEAM OFFTAKER Timely permits, licenses Public consent Technical, financial and environmental protection Offtake guarantee, inflation, exchange rate protection 60

61 PROJECT DEVELOPMENT Development of cogeneration project Construction Operation 61

62 Conclusions There is a need for a comprehensive Cogeneration Policy in ASEAN Huge potential for Cogeneration but market conditions differ from one country to another The driving force for industry to invest in Cogeneration is lower energy cost. This force is independent of overcapacity present in some countries Financing largest obstacle for cogeneration investment despite market liquidity 62

63 Cogeneration Weeks in 2004 Thailand Vietnam Singapore Indonesia Cambodia Philippines Malaysia March 6 9 April 20 April May 8 11 June June 6 8 July 63

64 Cogeneration Weeks in 2004 Policy day Training on cogeneration project development and on Technical -Financial Analysis Model Site visit / individual consultations EU/Local suppliers presentation on their cogeneration equipment and technologies 64

65 Other Major Events in 2004 COGEN 3 Seminar (Brussels, 25 February 2004) COGEN Europe Annual Conference (Brussels, February 2004) Power Gen Europe 2004 (Barcelona, May 2004) Power Gen Asia 2004 (Bangkok, 5 7 October 2004) Sustainable Energy Asia and Energy Efficiency Asia (Kuala Lumpur, November 2004) 65

66 For more information, please visit COGEN 3 Website at: Thank You! 66