Your experts in biomass pelleting Pellets: Howtomakemore fromyour woodchips and sawdust www.prodesa.net prodesa@prodesa.net
INDEX 1- THE COMPANY 2-MARKET POTENTIAL IN THE WEST COAST 3-CASE SCENARIO: FEASIBILITY STUDY OF A 100,000 mton/y PELLET PLANT 4-WOOD PELLET PRODUCTION PROCESS 5- SOME OF OUR REFERENCES
1. The company
THE COMPANY PRODESA is an engineering and manufacturing company specialised in the supply of turnkey pellet plants worldwide. CORE BUSSINES: Design and supply of turnkey plants. PRODESA is a global partner for complete pellet plants, biomass dryers and biomass fueled CHP plants. PRODESA has a sister company that takes care of the O&M contracts: SMART OPERATIONS. With its headquarters in Spain and branch offices in the US, Russia, France and Malaysia. More than 20 years of experience in the development of biomass plants and pellet plants. References between 20,000 mton/y and 460,000 mton/y
THE COMPANY The team of professionals that make up the workforce of PRODESA make it possible to cover all the stages of the project: Promotion and feasibility studies Basic and detailed engineering Manufacturing Assembly Start-up Training Technical after-sales assistance Plants and Operation
THE COMPANY Proven track record manufacturing and building pellet plants in different latitudes, climates and wood species. PRODESA is Not the standard EPC company, PRODESA is Specialized in pellets plants, so the customer benefits from all the advantages of experience and specialization.
PRODESA has a Strong Engineering Team in order to do all the process and manufacturing engineering in house. THE COMPANY PRODESA does the Automation & Programming in house.
THE COMPANY: INTERNATIONAL PRESENCE
WE BELONG TO
2. Market Potential in the West Coast
ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus 2016. H. Masaki Mita, Head of Japan Office, ARGUS
ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus 2016. H. Masaki Mita, Head of Japan Office, ARGUS
ARGUS PRESENTS TWO DIFFERENT SCENARIOS: Source: Argus 2016. H. Masaki Mita, Head of Japan Office, ARGUS
FUTUREMETRICS PRESENTS TWO DIFFERENT SCENARIOS: Source: Bill Strauss, President of Futuremetrics. Pellets Fuel Institute Conference 2016.
FUTUREMETRICS PRESENTS TWO DIFFERENT SCENARIOS: Source: Bill Strauss, President of Futuremetrics. Pellets Fuel Institute Conference 2016.
3.Case Scenario: FeasibilityStudyof a 100,000 mton/y Pellet Plant
JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL PELLET TONS mtons 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 1000 PELLET TON PRICE $/mt 160 160 160 160 160 160 160 160 160 160 160 160 1 REVENUE $ $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $16,000,0 COSTS OF GOODS SOLD RAW MATERIAL RAW MATERIAL mtons 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 1800 RAW MATERIAL COST $/mton 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30 COGS MATERIALS $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $5,400,0 FUEL FUEL mtons 2217 2217 2217 2217 2217 2217 2217 2217 2217 2217 2217 2217 266 FUEL COST $/mton 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30 COGS FUEL $ $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $798,0 ELECTRICITY CONSUMPTION kwh/ton 180 180 180 180 180 180 180 180 180 180 180 180 1 ELECTRICAL COSTS $/kwh 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.0 ELECTRICAL COSTS TON $/ton 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.6932807 11.693280 COGS ELECTRICITY $ $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $1,169,3 LABOR NUMBER OF SHIFTS 5 5 5 5 5 5 5 5 5 5 5 5 WORKERS PER SHIFT 4 4 4 4 4 4 4 4 4 4 4 4 TOTAL WORKERS 20 20 20 20 20 20 20 20 20 20 20 20 GROSS MONTHLY SALARY $ 3333 3333 3333 3333 3333 3333 3333 3333 3333 3333 3333 3333 400 SALARY $ 66667 66667 66667 66667 66667 66667 66667 66667 66667 66667 66667 66667 8000 CENTRAL SHIFT WORKERS 1 1 1 1 1 1 1 1 1 1 1 1 GROSS MONTHLY SALARY $ 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 500 CHIEF SALARY $ 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 4167 500 LABOR COSTS $ $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $850,0 PACKAGING BAGGING COST PER TON $/ton 0 0 0 0 0 0 0 0 0 0 0 0 PALLET COST PER TON $/ton 0 0 0 0 0 0 0 0 0 0 0 0 PACKAGING COSTS $ $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 MAINTENANCE COSTS SPARE AND WEAR PER TON $/ton 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5.18 5 MAINTENANCE COSTS $ $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $517,5 TOTAL COGS $ $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $8,734,8
JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL EXPENSES OCCUPANCY EXPENSES Insurance $ 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 45000 Maintenance $ 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 18000 Property Tax $ - - - - - - - - - - - - Rent $ - - - - - - - - - - - - Utilities (Water/Waste/Etc) $ 675 675 675 675 675 675 675 675 675 675 675 675 8100 TOTAL OCCUPANCY $ 5925 5925 5925 5925 5925 5925 5925 5925 5925 5925 5925 5925 71100 PAYROLL EXPENSE Wages $ 7500 7500 7500 7500 7500 7500 7500 7500 7500 7500 7500 7500 90000 Salaries $ 11250 11250 11250 11250 11250 11250 11250 11250 11250 11250 11250 11250 135000 Payroll Tax $ 1875 1875 1875 1875 1875 1875 1875 1875 1875 1875 1875 1875 22500 Workers Comp $ 750 750 750 750 750 750 750 750 750 750 750 750 9000 Employee Benefits $ 2700 2700 2700 2700 2700 2700 2700 2700 2700 2700 2700 2700 32400 TOTAL PAYROLL $ 24075 24075 24075 24075 24075 24075 24075 24075 24075 24075 24075 24075 288900 OPERATING EXPENSE Automobile $ 750 750 750 750 750 750 750 750 750 750 750 750 9000 Banking $ 225 225 225 225 225 225 225 225 225 225 225 225 2700 Computer $ 300 300 300 300 300 300 300 300 300 300 300 300 3600 Dues and subscriptions $ 150 150 150 150 150 150 150 150 150 150 150 150 1800 Equipment rental $ 825 825 825 825 825 825 825 825 825 825 825 825 9900 Fuel $ 11700 11700 11700 11700 11700 11700 11700 11700 11700 11700 11700 11700 140400 Insurance $ 6300 6300 6300 6300 6300 6300 6300 6300 6300 6300 6300 6300 75600 Miscellaneous $ 2250 2250 2250 2250 2250 2250 2250 2250 2250 2250 2250 2250 27000 Office Supplies $ 600 600 600 600 600 600 600 600 600 600 600 600 7200 Repairs and maintenance $ 3420 3420 3420 3420 3420 3420 3420 3420 3420 3420 3420 3420 41040 Shop tools and Suppliers $ 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 21600 Travel and Entertainment $ 900 900 900 900 900 900 900 900 900 900 900 900 10800 TOTAL OPERATING EXPENSE $ 29220 29220 29220 29220 29220 29220 29220 29220 29220 29220 29220 29220 350640 TOTAL EXPENSE $ $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $710,640 TOTAL COST COGS + EXPENSES $ $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $9,445,468 NET INCOME $ $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $6,554,532
JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL MEMO INPUTS tons 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 8333 100000 PELLET TON PRICE $/t 160 160 160 160 160 160 160 160 160 160 160 160 160 REVENUE $ $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $1,333,333 $16,000,000 COSTS OF GOODS SOLD COGS MATERIALS $ $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $450,000 $5,400,000 COGS FUEL $ $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $66,500 $798,000 COGS ELECTRICITY $ $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $97,444 $1,169,328 LABOR COSTS $ $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $70,833 $850,000 PACKAGING COSTS $ $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 MAINTENANCE COSTS $ $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $43,125 $517,500 TOTAL COST GOODS SOLD $ $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $727,902 $8,734,828 EXPENSES TOTAL OCCUPANCY $ $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $5,925 $71,100 TOTAL PAYROLL $ $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $24,075 $288,900 TOTAL OPERATING EXPENSE $ $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $29,220 $350,640 TOTAL EXPENSES $ $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $59,220 $710,640 TOTAL COST COGS + EXPENSES $ $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $787,122 $9,445,468 NET INCOME $ $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $546,211 $6,554,532 DEBT SERVICE DEBT SERVICE $ $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $158,965 $1,907,577 NET INCOME - DEBT SERVICE $ $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $387,246 $4,646,955
SUMMARY: INPUTS Price of pellets: 160 $/mton Price of raw material: 30 $/mton Price of fuel: 30 $/mton Price of electric energy: 0.065 $/kwh Labor costs: 40,000 $/year base worker 50,000 $/year foreman
SUMMARY: OUTPUTS Annual revenue: 16,000,000 $ (sales of pellets) COGS (cost of goods sold): Annual raw material cost: 5.400,000 $ (57.15%) Annual fuel cost: 798,000 $ (8.45%) Annual Electric cost: 1,169,328 $ (12.38%) Annual labor cost: 850,000 $ (9.0%) Annual maintenance cost: 517,500 $ (5.48%) Total annual COGS: 8,734,828 $ EXPENSES: Total Annual Expenses: 710,640 $ (7.52%) Net Income: Revenue COGS Expenses: 6,554,532 $ Debt Service: 1,907,577 $ (25% Equity, 5% interest rate, 15 years) Net income Debt service: 4,646,955 $
4. Wood pellet production process
LOGS CHIPS SAWDUST RAW MATERIAL COGENERATION WITH ORC Hot water DEBARKER DRUM CHIPPER HAMMER MILL BELT DRYER DRY PRODUCT STORAGE PELLETS PELLETING LINE BUFFER SILO MILLING LINE
PRELIMINARY LAYOUT
WOOD PELLETS PRODUCTION Raw material storage
WOOD PELLETS PRODUCTION Wood handling line DEBARKER CHIPPER WET HAMMER MILL
WOOD PELLETS PRODUCTION Drying line PRODESA manufactures its dryers under the license of the Swiss brand W. Kunz drytec AG, leader in the developement of thermal dryers which markets its products under the brand Swiss Combi since more than 40 years. DRUM DRYER HIGH TEMPERATURE BELT DRYER LOW TEMPERATURE Drying technology under the license of
WOOD PELLETS PRODUCTION Dry product storage Moisture content homogenization Flexibility in working hours: drying vs pelletizing Mechanical durability PELLET QUALITY
WOOD PELLETS PRODUCTION Milling line
WOOD PELLETS PRODUCTION Pelleting line
WOOD PELLETS PRODUCTION Pellet storage silos
WOOD PELLETS PRODUCTION Bagging and palletizing line
WOOD PELLETS PRODUCTION Supply of thermal energy BIOMASS FURNACE / HOT WATER BOILER BIOMASS CHP PLANT OTHERS: Residual energy(water steam, hot water, hot gases coming from other applications)
WOOD PELLETS PRODUCTION CHP Plants Our pellets plant design allow us to associate the pellets production to power generation by ORC system. This kind of plants increases the efficiency and feasability of project, becoming more profitable the economic investment.
WOOD PELLETS PRODUCTION Plant control and programming
WOOD PELLETS PRODUCTION Plant control and programming
5. SOME OF OUR REFERENCES
AVOTI High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant Latvia 110.000 ton/year Logs,chips, sawdust and shavings Industrial-Residential I1-A1 Yes (by the customer) PROCESS DATA Pretreatment Drying technology Dryer size Pellet capacity Debarking, chipping and milling Belt dryer 240 m2 15,9 tn/h Number of pellet mills 3 PELLETS OUTPUT Pellets storage Loading system 2 x 500m3 each By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT
ERTA Wood pellet plantand CHP plant GENERAL DATA Location Tarazona de la Mancha, Albacete (SPAIN) Pellet plant capacity 32.000 ton/year Raw material Logs, woodchips and sawdust Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC CHP 7 (by the customer) PROCESS DATA Pretreatment Debarking, chipping and milling Drying technology Belt dryer Dryer size 84 m2 Pellets capacity 8 ton/h Number of pellet mills 2 Electrical power capacity 680 kw PELLETS OUTPUT Pellets storage 4 silos x 500 m3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT
GRANORAMA High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant PROCESS DATA Pretreatment Drying technology Dryer size Dryer evaporation capacity Dryer thermal consumption Pellet capacity Number of pellet mills 6 PELLETS OUTPUT Pellets storage Truck loading system Rail loading system Lithuania 185.000 ton/year Logs, chips and sawdust Domestic EN PLUS A1 No Debarking, chipping and milling Belt dryer 2 x 212 m2 21,8 ton/h 21.600 kw hot water 90-60ºC 26 ton/h 4 vertical silos 10.200 m3/unit 3 vertical silos 13.400 m3/unit Yes Yes
GALPELLET Wood pellet plant and CHP plant GENERAL DATA Location Galicia (SPAIN) Pellet plant capacity 20.000 ton/year Raw material Woodchips Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC CHP 6 PROCESS DATA Pretreatment Wet milling Drying technology Belt dryer Dryer size 66 m2 Pellets capacity 3 ton/h Number of pellet mills 1 PELLETS OUTPUT Pellets storage 2 silos x 88,000 ft3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT
GENERAL DATA GREEN PELLET SARAWAK High capacity wood pellet plant Location Pellet plant capacity Raw material Primary end market Cogeneration plant PROCESS DATA Pretreatment Drying technology Dryer size Dryer evaporation capacity Dryer thermal consumption Pellets capacity Biomass boiler PELLETS OUTPUT Pellets storage Truck loading system Rail loading system Port investments Bintulu (MALAYSIA) 120.000 ton/year Acacia chips and waste veneer Co-firing in South Korean utilities No Chipping Belt dryer 157 m2 7,7 ton/h 6.800 kw 20 ton/h 4.756 kw Vertical silos 500 m3 Yes No No
GREEN PELLET SARAWAK High capacity wood pellet plant
RIBPELLET Wood pellet plant and CHP plant GENERAL DATA Location Huerta del Rey, Burgos (SPAIN) Pellet plant capacity 40.000 ton/year Raw material Logs and sawdust Primary end market Domestic use Pellet quality EN Plus A1 Cogeneration plant ORC - 1.255 kwe (by the customer) PROCESS DATA Pretreatment Debarking + chipping + milling Drying technology Belt dryer Dryer size 140 m2 Pellets capacity 8 ton/h Number of pellet mills 2 Electrical power capacity 1.255 kwe PELLETS OUTPUT Pellets storage 10 cells x 200 m3 each Loading system By truck PRODESA s ACTIVE ROLE - TURNKEY PROJECT
COLOMBO ENERGY (PORTUCEL Group) High capacity wood pellet plant GENERAL DATA Location Pellet plant capacity Raw material Primary end market Pellets quality Cogeneration plant Greenwood County, South Carolina (USA) 460.000 ton/year Logs and woodchips Industrial (European utilities) I2 No PROCESS DATA Pretreatment Drying technology Pellet capacity Debarking, chipping and milling Drum dryer 70 ton/h Number of hammer mills 5 Number of pellet mills 15 PELLETS OUTPUT Pellets storage Loading system 2 silos By rail PRODESA s ACTIVE ROLE (Milling and Pelleting line TURNKEY)
COLOMBO ENERGY (PORTUCEL Group) High capacity wood pellet plant
Forcus Martínez Sales Manager fmartinez@prodesa.net