ISSCT Trash utilization at sugarcane mills · Trash utilization at sugarcane mills ... steam generator EE EEE bagasse gas gas ... Energy production depends on gasification process.
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SULEIMAN HASSUANI 1
ISBUC 2009ISBUC 2009
ISSCTISSCT
ISBUC 2009ISBUC 2009
CTC CTC -- CENTRO DE TECNOLOGIA CANAVIEIRACENTRO DE TECNOLOGIA CANAVIEIRA
Trash utilization at sugarcane millsTrash utilization at sugarcane mills
A path to advanced biomass power generationA path to advanced biomass power generation
Suleiman Hassuani
suleiman@ctc.com.br
29 June 2009
SULEIMAN HASSUANI 2
ISBUC 2009ISBUC 2009
BAGASSE
BIOCHEMICALCONVERSION
COMBUSTION
GASIFICATION
EE/STEAM
ETANOL
STEAM / EE
FUELSFERTILIZERS
NEED OF ADDITIONAL BIOMASS
Energy conversion alternatives
TRASH
ProductsProducts for for thethe sugarcanesugarcane sectorsector
� Electricity
� Fuels – Etanol, Diesel, DME, Gasoline
� Fertilizers – NH3
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ISBUC 2009ISBUC 2009
How to increase electricity generationHow to increase electricity generation
1. Improve energy generation efficiency
� advanced technologies
2. Increase fuel availability
3. Reduce process steam/energy
consumption
SULEIMAN HASSUANI 4
ISBUC 2009ISBUC 2009
JUICEEXTRACTION
MILL PROCESS
Dryer
Gasifier
Gas cleaning
Gas turbine
Hot gasesgenerator
Heat recoverysteam generator
EE
EEE
bagasse
gas
gas
Condensingturbo
generator
gas
steam
bagasse
Turbogenerator
Advanced Technologies Advanced Technologies –– sugarcane mill integrationsugarcane mill integration
Gasification Gasification -- full integrationfull integration
steam
� Mill is totally dependent on energy for its processes.
� Energy production depends on gasification process.
� System is quite risky for integration at initial stages of technology development and commercialization.
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bagasse
MILL PROCESS
Boiler
Turbogenerator
STORAGE
ee
steam
vapor
bagasse
JUICEEXTRACTION � Increase in energy export is
made through high pressure boilers
� Energy export depends on process consumption
� Reduction in process consumption decreases energy export
� Electricity generation only during the season
Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration
Pure cogenerationPure cogeneration
SULEIMAN HASSUANI 6
ISBUC 2009ISBUC 2009
bagasse
Boiler
Turbogenerator
EE
steam
Condensingturbo generator
EE
bagasse
JUICEEXTRACTION
STORAGE
� The increase in energy export is made through:
1. The use of higher pressure boilers.
2. Reduction of process steam consumption
3. Increase efficiency of mechanical energy generation - electrification
4. Use of condensing steam turbo generators
5. Increase in the consumption of biomass (bagasse)
Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration
Cogeneration & condensingCogeneration & condensing
MILL PROCESS
steam
SULEIMAN HASSUANI 7
ISBUC 2009ISBUC 2009
bagasse
Boiler
Turbogenerator
EE
steam
steam
+ trash
Condensingturbo generator
Cleaning station bales
bagasse
JUICEEXTRACTION
STORAGE
Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration
Cogeneration & condensing with trashCogeneration & condensing with trash
MILL PROCESS
� The increase in energy export is made through all the previous conditions plus:
� Use of trash as additional renewable fuel
� Possibility to generate electricity year-round
EEEEEE
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ISBUC 2009ISBUC 2009
bagasse
Boiler
Turbogenerator
EE
steam
Cleaning station bales
JUICEEXTRACTION
+ trashbagasse
GASIFICATION
Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration
Gasification with trashGasification with trash
STORAGE
MILL PROCESS
steam
Condensingturbo generator
EEEE
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ISBUC 2009ISBUC 2009
bagasse
Boiler
Turbogenerator
EE
Cleaning station bales
Dryer
Gasifier
Gas cleaning
Gas turbine
Hot gasesgenerator
Heat recoverysteam generator
eeEEEE
bagasse+trash
gas
gas
Condensingsteam generator
gás
steam
JUICEEXTRACTION
STORAGE
Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration
Gasification with trashGasification with trash
MILL PROCESS
steam
steam
+ trashbagasse
Use of trash willprobably be necessary
to guarantee:year-round generation
& gasificationfeasibility
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ComparisonComparison ofof technologiestechnologies
PotentialPotential ofof electricityelectricity exportexport
Bagasse 62 bar
Bagasse 62 bar+ 50% trash 45% mc
Gasification stand alonebagasse+50% trash 45%mc
Gasification integratedbagasse+50% trash 45%mc
Gasification integratedbagasse+70% trash 15%mc
0
50
100
150
200
250
300
250300350400450500
Process steam consumption (kg/tc)
Esp
ecif
icel
ectr
icit
y ex
po
rt (
kWh
/tc)
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25Tops
1724Green leaves
8171Dry leaves
drywet%For each 1 t of cane stalks there is:
140 kg of dry trash (14%)
Trash potential
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First step towards trash accessibility
Pre harvest burning elimination impacts
� Field impacts
� Increase in harvester losses
� Reduction in harvester capacity
� Difficulties in field operations
� Changes in the ecosystem: herbicide effect, organic matter, soil moisture, etc.
� Industry impacts
� Increase in vegetal impurities
� Increase of soil in the process
� Reduction in milling capacity
� Increase in maintenance
� Process control difficulties
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ISBUC 2009ISBUC 2009
Trash available in the field
20 to 25% of the trash goes to the mill
with the cane
BAGASSE Cane fiber + trash
with the cane
Conventionalunburnedharvesting
75 to 80% of the trash stays in the field
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Trash recovery
Questions that should be answered
� How to collect the trash?
� How much trash should be collected?
� What is the impact of trash recovery in the field? – agronomy and equipment performance.
� What is the trash cost?
� What is the necessary industrial process?
� What is the impact in the industry?
� What are the gains???
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Saga of trash recovery effortSaga of trash recovery effort
Baler & Hay harvester – recovery from the soil
� Excessive number of equipment
� Traffic in the field
� Difficulties in management
� High humidity if it rains after harvesting
� Time limitations before cane sprout
� Excessive soil with trash (5 a 10%)
� Several maintenance problems.
� Baler: needs unbailing and trash shredding
� Hay harvester: no need of shredding but soil is incorporated to trash
� Low trash moisture content (10 – 15%)
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� Operational problems
� Reduced harvester reliability
� Need to increase harvester power
� Reduced harvester performance
� Difficulties in controlling vegetal impurities in the cane
� Reduced trash density
Saga of trash recovery effortSaga of trash recovery effort
Trash recovery from the harvester
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Saga of trash recovery effortSaga of trash recovery effort
Harvesting cane and trash – Partial Cleaning
Objective: Make feasible the best alternative to collect trash and cope with field operations
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Primary extractor
Secondary extractor
Cropdivider
Base cutter
Chopper
Topper
Roller feeding trainFinned roller
Knock down roller
Elevator
REDUCED SPEED
TURNED OFF
Saga of trash recovery effortSaga of trash recovery effort
Harvesting cane and trash – Partial Cleaning
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Harvesting with reduced fan speed
TRASH in the field TRASH with the cane
BAGASSE Cane fiber + leaves
and tops not separated
TRASHLeaves
separated at the Cleaning Station
50% 50%
Harvesting cane and trash
Partial Cleaning
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ISBUC 2009ISBUC 2009
Harvesting with reduced fan speed
TRASH in the field TRASH with the cane
BAGASSE Cane fiber + leaves
and tops not separated
TRASHLeaves
separated at the Cleaning Station
50% 50%
• Losses reduction• Fuel consumption reduction• Increased performance
• Agronomic benefits• Weed control• Erosion control
• Truck load reduction• Need of trash separation at mill• Need to process the trash
Partial Cleaning
Impacts
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Trash and soil separation from the cane at the industryTrash and soil separation from the cane at the industry
Cleaning station systemsCleaning station systems
Cane and trash
Air stream
Trash and soil
capture chamber
Feeding table separation
Air s
trea
m
Trash and soil capture chamber
Cane and trash
Between conveyors separation
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Trash processing
Soil removal and trash shredding
ROTARYSCREEN
SHREDDER
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• Shredding by cutting
• Operates even with high moisture
• Need of knives sharpening
Trash processing
Shredder
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18,0
17,0
17,0
Higher heating value (dry)
MJ/kg
3.10012,915Trash 1
1.7107,250Bagasse
2.2509,435Trash 2
kcal/kgMJ/kg
Lower heating valueMoisture content
(%)
Heating Value
48
45
O
-
0,1
S
-0,45,846Bagasse
0,20,66,448Trash
ClNHCUltimate Analysis* (%)
83143Bagasse
75169Trash
Volatile matterFixed CAshProximate Analysis* (%)
Trash as a fuel
Characterization of sugarcane trash
*Dry basis
*Dry basis
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Temperatures (oC)
13301260Bagasse
12601160Trash
FluidBeginning of
ash deformation
Trash as a fuel
Ash fusion
Whole trash bale burning in furnace
Trash high mineral impurities content
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Trash as a fuel – year round generation
Biomass storage
Traditional bagasse storage systems
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� With trash - Additional fuel
� Define generation strategy – season or year-round generation
� Impact on equipment and storage needs
� Bulk uncovered storage
� Soil preparation
� Location
� Piles form and size
� Equipment
� Need of covered storage: 7 days storage??
� Trash has to be burnt immediately, mixed to bagasse
Trash as a fuel – year round generation
Biomass storage
STORAGE BECOMES A RELEVANT ISSUE
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� Increase biomass by cane stalks fiber increase
� Parameters under study
� Impact on milling/diffusers capacity
� Impact on sugar extraction
� Impact on bagasse quality
� Impact on energy consumption of equipment
� Feasibility analysis
� Fiber optimized range
� Definition of new “contribution margin” equation
� Varieties development
Energy cane
Sugarcane high fiber content varietiesSugarcane high fiber content varieties
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Steps for the generation of considerable amounts EE Steps for the generation of considerable amounts EE
ConclusionsConclusions
0
50
100
150
200
250
300
250300350400450500
Process steam consumption (kg/tc)
Esp
ecif
icel
ectr
icit
y ex
po
rt (
kWh
/tc)
� Use high pressure steam boilers (above 65 bar)
� Use of steam extraction & condensing systems
� Electrification of mechanical power
� Reduce process steam consumption
� Use additional biomass: trash and cane fiber increase
� Use of advanced technologies –gasification combined cycle
Costs versus gains will define the technologies to be applied
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