8/6/2019 Sugar Cane as an Energy Crop - April 2006
1/26
1
Opportunities for development of aSugarcane Industry
Sugarcane as an Energy crop
Harold Davis and Paul Hough
April 2006
8/6/2019 Sugar Cane as an Energy Crop - April 2006
2/26
2
Prevailing Conditions Caribbean Sugar Industries characterised by high cost
Old Technologies, small factories and relatively high wages
Traditionally dependent on preferential prices for raw sugar
Significant price reductions from EU, the main preferential
market
8/6/2019 Sugar Cane as an Energy Crop - April 2006
3/26
3
Future of Sugarcane in the Caribbean
Raw sugar production can no longer
sustain an economically industry
Exploit the total biomass of this unique
crop
Electricity generation and ethanolwill become increasingly important
outputs from sugarcane production
8/6/2019 Sugar Cane as an Energy Crop - April 2006
4/26
4
Features of Guyana Industry
With a production capacity of 320,000 tonnes at unit cost18 per pound sugar, the Guyana Sugar Industry is
probably the most competitive in the SAC group This Industry is also challenged by the new market
prospects arising from the EU cuts
Guysuco has developed a long term strategic plan for costreduction based on expansion and improved efficiency.
8/6/2019 Sugar Cane as an Energy Crop - April 2006
5/26
5
Guysuco-Strategy-1998 Expand Industry & Diversify Product Base
Construct new 8400 tcd mill to produce refined sugar with co-
generation of 10MW electricity Possible joint venture potable alcohol distillery at new factory
Increase yields and reduce production costs on remainder of
industry
By 2010 sugar output 450,000 + tonnes
8/6/2019 Sugar Cane as an Energy Crop - April 2006
6/26
6
Strategy Implementation
Strategy revolves around reduction in production cost to 12 perpound sugar
Cost of operations largely dependent on labour intensive cane
cultivation and harvesting
Progress made with layout modification and reducing operatingcosts by increased mechanisation of agronomic practices
Collaborating with WICSCBS in variety evaluation for energy andother potential uses
24 MPC varieties being propagated
8/6/2019 Sugar Cane as an Energy Crop - April 2006
7/267
Characteristics DB 9633
DB 9633 DB 7869
120 tc/ha- Pl+2R 125 tc/ha Pl+2R
Pol% cane 13% - 14% Pol% cane ~ 12%
Fibre% cane 16%-18 % Fibre% cane 14% - 16%
8/6/2019 Sugar Cane as an Energy Crop - April 2006
8/268
Skeldon Project Milestones
1999-Commence land development for new sugarcane project atSkeldon
2001-Booker-Tate appointed Project Manger
2002 -World Bank clearance for financing
2003- EIA and Env Permit approved
2004 Agreement for cogeneration component with Power Companyand Financing bank
2005- Env Management Plan approved
2005- Factory Contracts signed
2006- Commence Factory Construction
8/6/2019 Sugar Cane as an Energy Crop - April 2006
9/269
Features of Skeldon Project
Net sugarcane cultivation to increase from 4270ha estate
and 310ha farmers to 8700 ha estate and 4250 ha farmers
Factory capacity 8400 tonnes cane per day
Crop duration 27 weeks net!
At steady state design capacity for 1,170,000 tonnes cane
and and production of 110,000 VHP sugar
8/6/2019 Sugar Cane as an Energy Crop - April 2006
10/2610
Features of Skeldon Project contd.
First diffuser in SAC industries
Rum distillery under consideration as joint venture with
Angostura Ltd. Factory will export 10MW to grid under firm power
agreement
Feasibility study and negotiations for refinery as jointregional venture in progress
Refinery may be sited at alternative Berbice factory givenSkeldons commitment to grid
8/6/2019 Sugar Cane as an Energy Crop - April 2006
11/2611
Cogeneration Plant Equipment
Two 125 tons/hr Boilers operating at 53 Bar and 485C
Extraction/Condensing T/A output 15MW
Back pressure T/A output 15MW Three Diesel Alternators combined output 10MW
Heavy Fuel Oil for Diesel Alternators
8/6/2019 Sugar Cane as an Energy Crop - April 2006
12/2612
Plant Operating Features
Sugar factory power - 9900 kW
Process steam - 168000 kg/hr
Cogen plant load - 2700 kW
Cogen plant steam - 5700 kg/hr
Bagasse prod @ 34%cane 400000 t
Bagasse consumed in crop 320000 t
Bagasse storage 54000 t
8/6/2019 Sugar Cane as an Energy Crop - April 2006
13/2613
Skeldon Cogeneration
operation Projected 10MWexport power from bagasse fired boilers for 37 weeks to
40 weeks including 10 weeks out of crop from stored bagasse
Projected 8MW export power from Diesel alternators when bagasse
stock exhausted Supplementing stored bagasse with imports from Albion will extend out
of crop generation period
6 week window of opportunity for fuel/mpc cane to supplement fuelsupply to plant after juice directed to distillery.
8/6/2019 Sugar Cane as an Energy Crop - April 2006
14/2614
Energy Content of Sugar-cane
(Guyana)1 Tonne Cane
110 kg sugar 1800MJ
170 kg stalk fibre 3100MJ140 kg top fibre(trash) 2600MJ
Tot. 7500MJ
1 tonne cane approx. equivalent to 1 barrel of oil
(ex Dr. M. Regis Leal -2003)
8/6/2019 Sugar Cane as an Energy Crop - April 2006
15/2615
Fuel Potential of Sugarcane
Potential for leaves and tops to contribute to boiler fuel
These should be removed prior to process for efficientextraction of sugars and fermentables
Cellulosic materials associated with alkali and alkaline earthions which can induce slag formation and reduce boilerefficiency
Bagasse has advantage over other cellulosic fuels becauseextraction and washing removes significant amounts ofalkalis and alkaline earths
8/6/2019 Sugar Cane as an Energy Crop - April 2006
16/2616
Meeting electrical requirements with back-pressure turbogenerators (atconstant steam demand)
Specificsteamdemand(%o
nbeetorcane)
Specific
electricitydemand(kW
h/tbeetorcane)
Electrical self-sufficiency (100 %) and generation of excess power for export (above 100 %)
150
%14013012011010090807060504030
1,5
0,4
160 170
export powerimport power
1,1
1,3
0,7
0,5
1,4
1,2
1,0
0,9
0,8
0,6
1,6
1,7mstPel
8/6/2019 Sugar Cane as an Energy Crop - April 2006
17/2617
Power Characteristics Integrated Factory with
Annexed Distillery
Front end consumption - 21kwh/t cane
Process consumption - 8 kwh/t cane
Pot export @45 bar 444 C - 92kwh/t cane
Pot export @ 82 bar 525 C - 143kwh/t cane
Distillery consumption ~ 4kwh/t cane
8/6/2019 Sugar Cane as an Energy Crop - April 2006
18/2618
Cogen Potential 4800TCD Case Study
Cane Production -``````926100t
5MW Plant - 47kwh/t cane10 MW Plant - 95kwh/t cane
12 MW Plant - 113kwh/t cane
15 MW Plant - 142kwh/t cane
Implies a 15 MW facility can probably be supported
8/6/2019 Sugar Cane as an Energy Crop - April 2006
19/26
19
Possible Sugar & Ethanol Production -Guyana Pol% cane 11%, Purity 81%
Standard Process EtOH from final molasses only- sugar
9% cane, EtOH 10l/t cane
A strike only sugar 6.1% on cane, EtOH 25l/t cane A & B strike sugar 7.6% on cane, EtOH- 17l/t cane
Ethanol only 60l/t cane to 66l/t cane
8/6/2019 Sugar Cane as an Energy Crop - April 2006
20/26
20
Ethanol Research 2002 -2004
4800 TCD factory could produce 74000 tonnes sugar and 11.3 M Litersof Ethanol
11.3 M Liters ethanol will permit 10% substitution in Gasolene
Ethanol production from factory generated molasses and fuel caneindicated to cost between 12 to 14 per Liter
Import price of Gasolene in 2003 - 24 per Liter
Gasolene spot price reached 37 per Liter in June 2005
8/6/2019 Sugar Cane as an Energy Crop - April 2006
21/26
21
Production 4800 TCD Case Study
Sugar - 73409t
Ethanol - 11.3M liters(a) Cogen 5MW - 42GWh
(b) Cogen 12 MW - 105GWh
8/6/2019 Sugar Cane as an Energy Crop - April 2006
22/26
22
Study Conclusions Integrated production of sugar, ethanol and energy as electricity offered
best economic potential from a factory of 4800 TCD capacity.
Fuel ethanol rapidly growing market possibilities including import
substitution by gasolene blends and export High fibre energy cane has potential role in extending crop to periods
of weather disruption for power and ethanol production
8/6/2019 Sugar Cane as an Energy Crop - April 2006
23/26
23
Commercial Ethanol prospects
Full feasibility to be conducted for a 12M liter fuel ethanoldistillery from non contract molasses
Strong interest expressed by investors in a 130M liter fuelethanol project from sugarcane on green field site
This project could support a 30MW cogeneration facility
8/6/2019 Sugar Cane as an Energy Crop - April 2006
24/26
24
Planned Future Projects
Guysuco future plans include expansions of Enmore,Blairmont and Albion factories to capacities of 4400 to 5100tcd.
Enmore is planned to be the focus of branded packagedsugar. Albion is being considered as an alternative site for arefinery
The expanded Enmore and Albion factories would have
cogeneration capabilities with minimum exports of 7MW
8/6/2019 Sugar Cane as an Energy Crop - April 2006
25/26
25
Next Steps Feasibility of Proposed factory expansions
Full Feasibility Study of Integrated Production Model
inclusive of ethanol production Support for national commitment to renewable energy with
recognition of the role of sugarcane
8/6/2019 Sugar Cane as an Energy Crop - April 2006
26/26
26
THANK YOU FOR YOUR
ATTENTION