Final Report Biomass

Department of Minerals and Energy Pretoria

Capacity Building in Energy Efficiency and Renewable Energy Report No. – 2.3.4 - 29

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa

This report contains restricted information and is for official use only

December 2004

Department of Minerals and Energy Pretoria

Capacity Building in Energy Efficiency and Renewable Energy

Report No. – 2.3.4 - 29

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa

December 2004

Report no. 2.3.4 - 29

Issue no. A

Date of issue December 2004

Prepared Sugar Milling Research Institute

Checked K. Naidoo / R. Hummelshoj

Approved A. Otto

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 1

Table of Contents

1 Executive Summary 4 1.1 Methodology 4 1.2 Biomass 5 1.3 HOMER/RE GIS proposal 7 1.4 Feasibility checklist 8

2 Glossary and Abbreviations 9 2.1 Glossary 9 2.2 General Abbreviations 10

3 Introduction 11

4 Methodology 12 4.1 Biomass Resources and their Characteristics 12 4.1.1 Desk Research 12 4.1.2 Field Research 12 4.1.3 Stakeholders Meeting 13 4.2 Questionnaire and visited companies/persons 13 4.3 Proposal for Linking Data to the HOMER/RE GIS 13 4.4 Development of an IPP Feasibility Checklist 14 4.5 Stakeholder Workshops 14

5 Biomass resources and their characteristics 15 5.1 Introduction 15 5.2 Bagasse 16 5.2.1 Sugar Industry 16 5.2.2 Sugarcane Biomass 18 5.2.3 Sugar Industry – Electricity Generation 20 5.3 Wood 21 5.3.1 Forestry Industry 21 5.3.2 Forestry Biomass 23 5.3.3 Forestry – Electricity Generation 25 5.4 Sawmill 25 5.4.1 Sawmill Industry 25

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 2 5.4.2 Sawmill Biomass 25 5.4.3 Sawmilling – Electricity Generation 27 5.5 Pulp and paper 27 5.5.1 Pulp and Paper Industry 27 5.5.2 Pulp and Paper - Biomass 28 5.5.3 Pulp and Paper – Electricity generation 30 5.6 Summary 30

6 Proposal of linking data to Homer/RE GIS 32 6.1 Background 32 6.1.1 Homer 32 6.1.2 The South African Renewable Energy Resource

Database 32 6.1.3 HomerGIS 34 6.2 Proposal to link data to HomerGIS 35 6.2.1 Option 1: Biomass Data Update 35 6.2.2 Option 2: Renewable Data Management Process 36 6.3 Conclusion 37

7 Feasibility check list 38 7.1 Background 38 7.2 General 38 7.3 Energy demand 38 7.4 Biomass / Waste Resource Available 39 7.5 Technical Evaluation 39 7.6 Economic Evaluation 39 7.7 Environmental Conditions and Legislation 40 7.8 Case Example in the sugar industry 42 7.9 Check List 45

8 Conclusion and Recommendations 47

9 References 49

Table of Appendices

Appendix 1 – Area, Cane and Bagasse properties Appendix 2 – Cane and Bagasse properties 2003/04 Season Appendix 3 – Power generation potential Appendix 4 – Sugar mill Questionnaire Appendix 5 – Sawmill Questionnaire Appendix 6 – Pulp and Paper Questionnaire Appendix 7 – Terms of Reference

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 3 Appendix 8 – Contacts in Biomass


1 Executive Summary

The Department of Minerals and Energy (DME), South Africa is responsible for formulating strategies and drafting legislation for the South African energy sector. The Directorate Renewable Energy in the DME has finalised the White Paper on Renewable Energy (RE). This Paper reflects a renewable energy tar-get of 10 000 GWh (0.8 Mtoe) by 2013, to be produced mainly from biomass, wind, solar and small-scale hydro. The renewable energy is to be utilised for power generation and non–electrical technologies such as solar water heating and bio-fuels.

This study relates to the exploitation of commercially based biomass resources for electricity generation. According to a macro economic study on utilising renewable energy resources in South Africa, electricity production from com-mercially based biomass is among the most cost effective for renewable energy applications. Assuming a least-cost approach for implementation of renewable energy applications, a major contribution to the RE target can be derived from commercially available biomass resources. Detailed data on biomass resources (bagasse, pulp and forest wood waste and sawmill wood waste), energy content and physical/chemical characteristics are presently not easily accessible. This information is needed to determine the actual potential of power generation from biomass and to establish a reliable basis to enable possible IPP’s to carry out due diligence studies as part of possible project preparations.

1.1 Methodology Information was available in various formats: from existing published re-ports/documents; and from interviews conducted with carefully selected people working at various levels in the different industries. In an early stage of the project a stakeholders meeting was held (17 people at-tended). The purpose of the meeting was to raise the necessary interest in the project while at the same time engaging in a consulting process with key role players in the different industries. Questionnaires were developed and approved by the project team to assist in the data acquisition process. Supporting letters were issued by the Department of Minerals and Energy (DME) to give the request for information the neces-sary legitimacy.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 5 The consultant in conjunction with DME/COWI discussed the format of the data suitable for linking to the HOMER/RE GIS. An external consultant from the CSIR who has been involved in the development of the HOMER/RE GIS interface was approached to write a proposal for linking the data. A feasibility checklist for Independent Power Producers was developed by rep-resentatives from COWI. This list includes technical, financial, legislative and environmental factors to consider when engaging in power generation. In close consultation and interaction with DME and the Local Renewable En-ergy Adviser a final workshop was held on 24 November 2004. The aim of the workshop was to present the findings of the study and to gain feedback from the workshop delegates. The workshop was attended by 33 delegates represent-ing the sugar, forestry, sawmilling and pulp and paper industries as well as government and non-government organisations with special interest in renew-able energy. The final report of this study includes a description of the applied methodology, results of the questionnaires/visits, presentation of the collected data and infor-mation, as well as a proposal for linking the data into the South African Re-newable Energy Resource Database (SARERD).

1.2 Biomass

Commercial biomass in South Africa is mainly produced by the sugar industry, the forest industry, the sawmilling industry and the pulp and paper industry. The majority of this biomass is found in Mpumalanga and KwaZulu-Natal with small amounts in the Eastern Cape, Limpopo, Western Cape and Gauteng. Ta-ble 1 shows the biomass per sector.

In the sugar industry the biomass waste consists of bagasse and field residue. The amount of field residue depends on the harvesting method. With green harvesting (no field burning) the total sugarcane biomass waste can be as high as 11.47 million tons with an energy content of 22.33 TWh. The potential elec-tricity that can be generated from this biomass is about 5 500 GWh (3 000 GWh from bagasse alone). This is in excess of the industry’s own requirement which is about 700 GWh.

The biomass from timber is all the wood not suitable for commercial use that accumulates during the growing and harvesting of the timber. This total forest biomass waste is about 3.13 million tons with an energy content of 10.89 TWh. Burning the biomass in a conventional boiler as part of an efficient steam cycle could produce about 2 722 GWh.

The sawmilling industry produces chips, sawdust and bark as biomass waste. The total biomass waste is about 2.95 million tons with an energy content of 8.49 TWh. This translates into an annual electricity production of approxi-mately 2 122 GWh. Although the power and steam requirements in the saw-milling industry are not known, it is believed that this electricity will mainly be

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 6 needed in-house to substitute any ESKOM power. There would therefore be very little opportunity for export power.

The total pulp and paper industry biomass waste is about 5.78 million tons with an energy content of 10.17 TWh. About 90% of this biomass is black liquor with an energy content of 9.03 TWh, while the remainder consists of sludge and bark. Black liquor is only produced by the chemical pulping process and is usually burnt to recover chemicals. The biomass has a potential electricity ca-pacity of about 2 542 GWh. Again it is believed that most of the energy will be used to meet in-house energy requirements with little or no opportunity for the export of electricity.

Table 1. Biomass per sector

Industry Biomass NCV Mass Energy Power content potential MJ/t 1000 t TWh GWh

Sugar Field residue 6 894 5 336 10.21 2 553 Bagasse 7 117 6 136 12.12 3 031

Forestry Softwood 13 016 1 588 5.74 1 650 Hardwood 11 820 1 555 5.11 1 073

Sawmill Chips 10 316 1 433 4.11 1 162 Dust 10 611 730 2.15 608 Bark 10 135 443 1.25 353

Pulp & Paper Black liquor 6 243 5 206 9.03 2 257 Sludge 5 777 234 0.38 94 Bark 7 975 345 0.76 191

Total 7 958 23 006 50.86 12 972

Successful use of biomass energy rests largely on the conversion system adopted. The most suitable technology can vary from biomass to biomass and region to region. While some of the new technologies are looking promising, presently for most applications conventional combustion technology is still the most appropriate.

In a dedicated electricity facility without heat recovery it should be possible to achieve a conversion of 25% resulting in an estimated electricity production from total biomass of over 13 000 GWh. In practice this is expected to be much lower for the following reasons:

• Not all the biomass is easily available. In the sugar industry the field residue (trash and tops) is spread out over some 430 000 hectares. In the forest industry all the biomass is on the plantations covering well over 1.3 million hectares. It might be impractical, undesirable and prohibi-tively expensive to collect the biomass from cane fields and timber plantations.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 7 • The conversion efficiency of 25% power on fuel is based on the total

biomass being used for electricity generation in a high-pressure con-densing steam cycle, boiler combustion process (8 000 kPa(a), 520°C). Any deviation from such a system will obviously result in a different efficiency e.g. when operating backpressure turbo alternators to supply steam to process, potential electricity output will be reduced.

• In the sugar industry the quantity and composition of the biomass is well recorded and the data is readily available. In the other industries quantities are often measured in volumes rather than in mass and there is particular uncertainty about the moisture content of the biomass. The latter has a significant effect on the net caloric value and therefore on the energy content of the biomass.

The most promising source of biomass is sugarcane bagasse. It is already being used to meet the industry’s in-house steam and power requirements. Increasing the efficient use and generation of energy within the industry can easily result in a potential capacity of 2800 GWh with in-house requirements of only 700 GWh.

1.3 HOMER/RE GIS proposal

Two possible approaches to link data collated as part of this study to the Homer/RE GIS program are proposed.

The first proposal is to update the existing biomass grid layers and make them available for HomerGIS. Given that all the current biomass data is held within one biomass layer, it is recommended that the HomerGIS model be upgraded to have individual biomass layers for different types of crops. Subsequent updat-ing of the individual biomass layers could be undertaken without having to re-process and consolidate all the other biomass data simultaneously.

The second proposal is to extend the above update within the context of a sig-nificantly more strategic approach to the whole issue of Renewable Energy Re-sources information. It is proposed that a project be initiated that seeks to achieve the following:

1. Develop a plan of action for the ongoing management of information for renewable energy resources.

2. Recommend an appropriate body to carry out this management (on a permanent basis).

3. Ensure that all current projects collecting data on renewable energy re-sources be effectively coordinated (to ensure consistency of approach; avoid redundant efforts, and so on).

4. Collate all collected data and have it transformed, if need be, into a readily accessible format (or formats) useable by currently known tools.

5. Make available – preferably on-line – a national set of “best available” data sets related to renewable energy resources.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 8 1.4 Feasibility checklist As per Terms of Reference a feasibility checklist was compiled to assist poten-tial independent power producers with renewable energy projects in the bio-mass sectors. The list is by no means exhaustive.


2 Glossary and Abbreviations

2.1 Glossary

Imbibition Cane wash water.

Independent power producers (IPPs) – producers of power (electricity), which sell their power to electricity distributors for supplying to the national electricity grid.

Mtoe (Million tons of oil equivalent) A universal unit of comparison in which all energy can be measured. (1 Toe = 42 GJ = 0.042 TJ = 0.012 GWh).

Power Watt (W) 1 Joule per second of energy consumption or dissipa-

tion (MW = million W).

Megawatt (MW) A unit of power. One Megawatt is equal to 1 000 kilo-watts or about 1340 horsepower.

Energy Kilowatt-hour (kWh) A unit of energy consumption. One kilowatt hour is

equal to 3.6 MJ (Megajoules) or 3 412.14 Btu (British thermal units) or 859.855 kcals (kilocalories).

Megawatt hour (MWh) A unit of energy consumption. One Megawatt hour is the amount of energy consumed in one hour at a rate of one Megawatt.

Gigawatt hour (GWh) A unit of energy consumption. One Gigawatt hour is equal to 1 000 Megawatt hour.

Terawatt hour (TWh) A unit of energy consumption. One Terawatt hour is equal to 1 000 Gigawatt hour.

kWh/tc Kilowatt hour per ton of cane.


Biomass Ash Inorganic component in biomass (inert material that

does not take part in the combustion process).

Brix Soluble organic component in biomass.

Fibre Insoluble organic component in biomass (mainly cellu-lose, hemicellulose and lignin).

2.2 General Abbreviations BEE Black Economic Empowerment CDM Clean Development Mechanism CER Certified Emissions Reduction CSIR Council for Scientific and Industrial Research (South Africa) DME Department of Minerals and Energy (South Africa) ESKOM Electricity Supply Commission (South Africa) IPP Independent Power Producer RE Renewable Energy HOMER Hybrid Optimisation Model for Electric Renewables GIS Geographic Information System SARERD South African Renewable Energy Resource Database GCV Gross Calorific Value NCV Net Calorific Value


3 Introduction

The Department of Minerals and Energy (DME), South Africa is responsible for formulating strategies and drafting legislation for the South African energy sector. The Directorate Renewable Energy in the DME has finalised the White Paper on Renewable Energy (RE). This Paper reflects a renewable energy tar-get of 10 000 GWh (0.8 Mtoe) by 2013, to be produced mainly from biomass, wind, solar and small-scale hydro. The renewable energy is to be utilised for power generation and non–electrical technologies such as solar water heating and bio-fuels.

As a result of a dialogue between the DME and Danida over the years 1999 to 2001 the Project "Capacity Building in DME in Energy Efficiency (EE) and Renewable Energy (RE) (CaBEERE), has been formulated.

The CaBEERE Project aims at enhancing DME´s capacity and performance by assisting in developing programmatic approaches through strategies and action plans for energy efficiency and renewable energy in transparent co-operation with relevant stakeholders. The project aims at making the DME a "learning organisation" better able to update, develop and implement strategies and ac-tion plans within EE and RE. The project approach is primarily built on learn-ing by doing through on the job training of DME staff and other stakeholders. At the end of the project DME will be able to effectively and efficiently meet its energy efficiency and renewable energy mandate as prescribed by the White Paper on Energy Policy and to sustain this capacity.

The ToR relate to the exploitation of commercially based biomass resources for electricity generation. According to a macro economic study on utilising re-newable energy resources in South Africa, electricity production based on commercially based biomass is among the most cost effective for renewable energy applications. Assuming a least-cost approach for implementation of renewable energy applications, a major contribution to the RE target can be de-rived from commercially available biomass resources. Detailed data on bio-mass resources (bagasse, pulp and forest wood waste and sawmill wood waste), energy content and physical/chemical characteristics are presently not easily accessible. This information is needed to determine the actual potential of power generation from biomass and to establish a reliable basis to enable pos-sible IPP’s to carry out due diligence studies as part of possible project prepara-tions.


4 Methodology

4.1 Biomass Resources and their Characteristics Input data for this section was obtained from two sources: Industry Associa-tions/Specialist Institutes and existing businesses operating in the three focus industries (i.e. Sugar/bagasse; Pulp and Paper and Saw Milling). Information was available in various formats: from existing published re-ports/documents; and from interviews conducted with carefully selected people working at various levels in the different industries.

4.1.1 Desk Research The desktop study and literature survey was carried out as a preliminary study to obtain the readily available data on biomass and an overview of the industry producing that biomass. The outcome of this preliminary study also identified the information “gaps” that needed to be filled from interviews. A first interim report including a draft questionnaire was submitted to the project team for ap-proval and possible refocus of the study. The Terms of Reference for this study includes the following list of materials as being the essential background reading that are relevant to this study:

• Energy White Paper 1998, DME

• Renewable Energy White Paper 2003, DME

• Economic and Financial Calculations and Modelling for the Renewable Energy Strategy Formulation, DME/Danida 2004.

4.1.2 Field Research The field research stage of the project was to some degree dependent on the outcome of the desktop study. Given the information gaps and project refocus, interviews were conducted with various role players in the different sectors. Be-cause of time and budget constraints the number of interviews for the different sec-tors had to be reduced and were partly conducted telephonically and by correspon-dence. The outcome of this part of the study is a detailed overview of the quan-tity and quality of biomass for the different sectors in the various regions.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 13 4.1.3 Stakeholders Meeting In an early stage of the project a stakeholders meeting was held. The purpose of the meeting was to raise the necessary interest in the project while at the same time engaging in a consulting process with key role players in the different in-dustries. The meeting was attended by 17 senior representatives of the four sec-tors and provided a useful exchange of information. It was suggested that black liquor, a waste product of the pulp and paper industry, should be included in the list of potential commercially exploitable resources. Agreement was reached with respect to biomass in the other sectors.

4.2 Questionnaire and visited companies/persons Questionnaires were developed to assist in the data acquisition process. The questionnaires were approved by the project team. Supporting letters were is-sued by the Department of Minerals and Energy (DME) to give the request for information the necessary legitimacy. Returned questionnaires can be found in Appendixes 4, 5 and 6. Biomass contacts made during the study are given in Appendix 8 grouped by industry.

All 14 sugar mills were sent questionnaires by e-mail. In most cases the ques-tionnaires were followed up by further correspondence, a telephone call or fac-tory visit. In the end all mills responded positively and returned completed questionnaires.

For the forest industry no questionnaire was deemed necessary because of the limited role players (Mondi and Sappi) and the excellent data available on the internet (www.forestry.co.za). In addition, information was obtained from ex-pert interviews within Global Forest Products, Forestry South Africa and repre-sentatives from Sappi and Mondi.

The sawmilling industry consists of over 100 sawmills mainly in Mpumalanga and KwaZulu-Natal. A total of 4 questionnaires were sent out in this industry. No return questionnaires were received and most information gathered was done through personal visits (Singini, Wesa, Langini, Graskop, Tweefontein and Sabie). Two key role players in the sawmilling industry are Hans Merensky Holdings (Pty) Ltd, the biggest sawmilling company with various factories, and Crickmay & Associates a consulting firm in Pietermaritzburg with extensive experience in the sawmilling industry.

In the pulp and paper industry 8 questionnaires were sent out. Only 6 returns were received: Sappi (Saicorr, Stanger, Ngodwana and Tugela); Mondi (Piet Retief and Richards Bay).

4.3 Proposal for Linking Data to the HOMER/RE GIS The consultant in conjunction with DME/COWI discussed the format of the data suitable for linking to the HOMER/RE GIS. An external consultant from the CSIR who has been involved in the development of the HOMER/RE GIS interface was approached to write a proposal for linking the data.

http://www.forestry.co.za/

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 14 4.4 Development of an IPP Feasibility Checklist It was decided that the development of an IPP feasibility checklist was the main responsibility of DME/COWI. Industry specific hurdles were obtained from the relevant industries as part of the interview process during the field research.

4.5 Stakeholder Workshops The process was driven by the consultant in close consultation and interaction with DME and the Local Renewable Energy Adviser. This involved selecting workshop participants in consultation with DME/CaBEERE personnel. In total 33 people attended the combined workshop on 24 November 2004 for the four sectors i.e. sugarcane, forestry, sawmilling and pulp and paper. In preparation for the workshop, participants were sent a draft copy of the final report. Delegates were invited to comment on the report and were given a dead-line of 29 November 2004 to do so.


5 Biomass resources and their characteristics

5.1 Introduction One of the key characteristics of biomass as an energy source is the calorific value. The importance of this property and the confusion about the term dis-played in the literature warrants a short note on its definition and determination.

There are two different calorific values, a gross calorific value (GCV) and a net calorific value (NCV). The GCV is the total energy released during the com-bustion process and can only be accurately determined by using a bomb calo-rimeter at the standard electro-chemical temperature of 25°C. The NCV is the GCV minus the latent heat of the water formed by the combustion process and is obtained by calculation. The experimental procedure and method of calcula-tion are laid down in ISO 1928 (Anon, 1995).

Any substance consists of organic matter, moisture and inorganic matter or ash. Only the organic matter takes part in the combustion process. Although mois-ture and ash are inert they do influence the gross calorific value of the biomass as a whole. For that reason it is important to quote the gross calorific value of the biomass on a dry ash free basis which is the same as the gross calorific value of the organic matter only.

The gross calorific value of the biomass (GCVB) can now be expressed as a function of the gross calorific value of the organic matter (GCVO), the ash con-tent (A) and the moisture content (M):

GCVB = GCVO – GCVO / 100 * A – GCVO / 100 * M

The net calorific value is the gross calorific value minus the latent heat of the water formed by the combustion process at a temperature of 25°C. On a dry ash free basis the only water formed is through the reaction of oxygen with the hy-drogen in the biomass. Hence the net calorific value of the organic matter (NCVO) can be expressed as a function of the gross calorific value of the organic matter (GCVO) and the hydrogen content of the organic matter (H):

NCVo = GCVO – 18 / 2 * 2441 / 100 * H

For the biomass as a whole allowance has to be made for the ash and moisture content of that biomass. In addition a correction should be made for the latent

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 16 heat of the moisture. The net calorific value of the biomass (NCVB) can be ex-pressed as a function of the net calorific value of the organic matter (NCVO), the ash content (A) and the moisture content (M):

NCVB = NCVO – NCVO / 100 * A – (NCVO + 2441) / 100 * M

For a fibrous material (dry, and ash free) the gross calorific value is in the order of 20 000 MJ/t and the hydrogen content is typically 6.1%. This results in a net calorific value of 18 660 MJ/t. The biggest unknown in establishing the calo-rific value of the biomass as a whole, which includes moisture and ash, is the moisture content. For green wood this moisture content varies from tree to tree and within the different parts of the tree and ranges between 25 and 65%.

5.2 Bagasse

5.2.1 Sugar Industry The South African Sugar Association is a partnership between the SA Cane Growers Association and the SA Sugar Millers Association. The former admin-isters the interests of about 47 000 registered cane growers with a total area un-der cane of over 430 000 hectares. Of these cane growers about 2000 are large commercial farmers and some 45 000 are small-scale growers farming on tribal land. The large-scale commercial farmers are responsible for more than 66% of total sugarcane production while small-scale growers produce approximately 17.5% of the total crop.

Table 2. South African sugar mills

Company Sugar mill Comments

Illovo Sugar ES Eston NB Noodsberg Refinery PG Pongola Refinery SZ Sezela Furfural UF Umfolozi Refinery UK Umzimkulu

Tongaat-Hulett AK Amatikulu DL Darnall FX Felixton Paper, Cogeneration EN Entumeni Closed in January 2004 MS Maidstone Cogeneration, Animal feed Transvaal KM Komati Cogeneration ML Malelane Refinery UShukela GH Gledhow Refinery, Paper Union Coop UC Union Co-op Wattle, Maize

Milling companies with their own sugar estates produce 16.5% of the crop. This percentage is likely to decrease as companies continue to promote medium-scale

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 17 farming for the economic development and empowerment of previously disadvan-taged people. The number of people employed in the sugarcane agriculture sec-tor is 74 000 and sugarcane production is over 20 million tons per annum.

The SA Sugar Millers Association administers the interests of the five milling companies. The milling sector employs 11 000 people in 15 sugar mills: six mills are owned by Illovo Sugar Limited, five mills owned by Tongaat-Hulett Sugar Limited, two mills by Transvaal Sugar Limited, one co-operative owned by growers (Union Co-op) and one mill owned by the BEE company Ushukela Sugar (Table 2). Komati and Malelane are situated in Mpumalanga, the other 12 mills are in KwaZulu-Natal. Five of the mills are known as ‘white-end’ mills pro-ducing their own refined sugar. Raw sugar from the other nine mills is routed di-rectly to Durban where it is either refined at the central Tongaat-Hulett Refinery or stored at the South African Sugar Association Bulk Terminal prior to export. Total sugar production is in the order of 2.4 million tons of which 1.3 million is for the local market and 1.1 million for the export market. Turnover of the sugar industry is about ZAR 6 billion. Illovo Sugar Limited is listed directly on the Johannesburg Stock Exchange and Tongaat-Hulett Sugar and Transvaal Sugar indirectly through their holding companies Anglo American and Rembrandt.

Cane is grown in KwaZulu-Natal and to a lesser extent in Mpumalanga (Figure 1). In KwaZulu-Natal the cane growing area is about 386 000 hectares primar-ily situated on the coast with some cane grown around Pietermaritzburg. In Mpumalanga the total area under cane in 2003 was 47 000 hectares.

0

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KZN Mpum E Cape Limpopo W Cape Gauteng

1000

ha

Cane

Figure 1. Sugarcane area by province in 2003

In KwaZulu-Natal the cane is mainly rain fed and the average cane yield is in the order of 43 t/ha/y resulting in 16.44 million tons of cane in 2003. In Mpu-malanga the cane is irrigated giving a much higher yield of about 85 t/ha/y or almost 4 million tons of cane per annum (Figure 2).


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tons Cane

Figure 2. Sugarcane yield by province in 2003

5.2.2 Sugarcane Biomass The processing of sugarcane produces two sources of biomass; the residue left in the field after harvesting (tops and trash) and bagasse, a residue from the processing of cane.

Tops and Trash. During the harvesting process, tops (14%) and trash (8%) are removed and ideally only the stalks (78%) are delivered to the factories. The trash is usually removed by burning and the tops are cut by hand and left in the field. Leaving tops and trash in the field is seen by many agronomists as bene-ficial because of their nutritional value, contribution to weed control, protection against erosion and retention of moisture in the soil. However, the tops and trash combined provide a considerable amount of fuel and ways of recovering them are presently being explored. The quantity and quality of stalk, trash and tops varies significantly and depends on things like cane variety, cane maturity and rainfall. Table 3 gives some tentative figures for the amounts and properties of the different parts of the cane plant. These figures are based on 20 million tons of cane.

Table 3. Properties of cane stalk, trash and tops

Mass Fibre Brix Moisture Ash NCV Energy 1000 t % % % % MJ/t TWh

Stalk 19 711 12.17 15.94 70.44 1.45 2 917 15.96

Trash 2 001 82.50 2.20 12.30 3.00 15 097 8.39Tops 3 623 23.40 3.80 69.80 3.00 3 145 3.16

Total 25 336 19.33 13.12 65.76 1.79 3 912 27.52

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 19 In practice, the residue left in the field will be a mixture of stalk, trash and tops. The composition of that mixture depends very much on the harvesting practice. Table 4 gives the residue made up of 2% stalk, 84% trash and 90% tops based on 20 million tons of cane.

Table 4. Properties of cane and residue


Residue 5 336 41.19 4.19 51.73 2.89 6 894 10.21Cane 20 000 13.50 15.50 69.50 1.50 3 116 17.31

Total 25 336 19.33 13.12 65.76 1.79 3 912 27.52

Bagasse. The second source of biomass from sugarcane is bagasse. Bagasse is the residue that remains after the processing of the cane in the factory. It has the advantage that it is already at a central point and can be burnt in specially de-signed boilers without any pre-treatment. The quantity of bagasse is fairly con-stant at just over 30% on cane. Table 5 gives the tons of bagasse from 20 mil-lion tons of cane and some typical values for the fibre, brix, moisture and ash content of that bagasse.

Table 5. Properties of bagasse


Bagasse 6 136 44.00 2.00 50.00 4.00 7 117 12.12

In the South African sugar industry the subject of the calorific value of bagasse has been well researched (Don et al., 1977 and Wienese, 1999). This research lead to the development of the following generic equation for the net calorific value (NCV) as a function of the moisture (M), the Brix (B) or dry solids and the Ash (A).

A*182,60-B*31,14-M*207,01-18260NCV =

This equation is based on a Gross Calorific Value (GCV) of fibre and brix of 19 605 and 16 491 MJ/t respectively and a hydrogen content of 6.17% on a dry ash free basis. Although the equation was developed for bagasse, with some cir-cumspection it can also be used for the residue left in the field without too much error. Table 6 shows the estimated bagasse and residue in the case of green harvesting (no burning) per province.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 20 Table 6. Sugarcane biomass waste by province

KZN Mpum E Cape Limpopo W Cape Gauteng 1000 t 1000 t 1000 t 1000 t 1000l t 1000 t

Residue 4 429 907 0 0 0 0Bagasse 5 093 1 043 0 0 0 0

Total 9 522 1 950 0 0 0 0

Figure 3 shows the energy content of that bagasse and residue in the two cane growing regions KwaZulu-Natal and Mpumalanga.

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Figure 3. Energy content of sugarcane biomass waste by province in 2003

Sugar industry data for the last ten years including cane supply area, cane crushed and bagasse produced per sugar factory are given in Appendix 1. The same information is supplied on a monthly basis for the 2003/2004 crushing season in Appendix 2.

5.2.3 Sugar Industry – Electricity Generation The total sugarcane biomass waste is about 11.47 million tons with an energy content of 22.33 TWh. However, because of the alleged benefit of leaving some trash and tops in the field and the problems associated with collecting the field residue in practice only bagasse is available for electricity generation. This ba-gasse amounts to 6.14 million tons with a total energy content of 12.12 TWh.

During normal operation a sugar factory usually generates its own electricity. The need for additional fuel (mostly coal) varies from factory to factory and from time to time. It depends mainly on factory and process design, the steadi-ness of operation and the fibre content of the cane. Most raw sugar factories are designed to use a minimum of coal to avoid the need for a costly bagasse dis-posal system. Other factories are fitted with a back-end refinery (ML, PG, UF, GH and NB) or are exporting bagasse (ML, FX, GH, MS and SZ) and burning

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 21 significant amounts of coal. At present only KM, FX and MS are doing a little co-generation (See Table 2 for mill abbreviations).

The industry has the potential to export significant amounts of electricity to the grid. However, this requires a reduction in power and process steam require-ments and an increase in power generation efficiency i.e. high pressure boilers and a combination of efficient back pressure and condensing turbo-alternators. At an anticipated conversion rate of 25% power to fuel, the estimated total po-tential electricity from sugarcane biomass is about 5 500 GWh, from bagasse alone it is roughly 3 000 GWh and the in-house requirements are 700 GWh. Appendix 3 gives the electricity generation potential for the sugar industry based on the following assumptions:

• Cane throughput as per Appendix 1 • Bagasse quantity and quality including NCV as per Appendix 1 • Process steam on cane (45% for a raw sugar factory and 55% for a

sugar factory with a backend refinery) • In-house power on cane (35 kW/tc for a raw sugar factory and 40 kW/tc

for a sugar factory with a backend refinery) • Boiler steam pressure and temperature (8000 kPa(abs) and 520°C) • Back pressure turbine exhaust steam pressure (200 kPa(abs)) • Condensing turbine exhaust steam pressure (15 kPa(abs)) • Boiler efficiency (85%) • Boiler feed water temperature (116°C) • Boiler blow down (5%) • Turbine efficiencies (saturated exhaust steam conditions)

It is believed that these assumptions are achievable and leave room for further improvements.

5.3 Wood

5.3.1 Forestry Industry In 2003 the total area of commercial timber plantations was 1 371 625 hectares of which 52% was planted with softwood and 48% with hardwood. The soft-wood is mainly pine and the hardwood consists of 40% of the fast growing eucalypts and 8% of wattle or acacia. In the same year the annual yield was 16.86 million tons (19.2 million m3) of timber; 8.69 million tons (8.4 million m3) of softwood and 8.17 million tons (10.8 million m3) of hardwood. Timber production was about 12 tons per hectare for softwood and hardwood alike. The plantation area and the production of timber by wood type is summarised in Table 7.

Table 7. Production of timber by wood type

Area Mass 1000 ha % 1000 t %

Soft Wood 709 52 8 692 51Hard Wood 662 48 8 172 49

Total 1 372 100 16 864 100


Of the total plantation area 57% is managed for the pulp and paper industry, 36% for the sawmill industry, 5% for the mines and 2% for other purposes. Of the 16.86 million tons 60% went to pulp and paper, 33% to sawlogs and the remaining 7% to the mines and other destinations. The plantation area and the production of timber by product type is summarised in Table 8.

Table 8. Production of timber by product

Area Mass 1000 ha % 1000 t %

Pulp & Paper 786 57 10 093 60Sawlog 488 36 5 582 33Others 98 7 1 189 7

Total 1 372 100 16 864 100

Private sector ownership (private companies, individuals, partnerships, trusts) accounts for 78%, whilst state and municipalities own 22% of the total planta-tion area. About half of the softwood plantations are privately and half publicly owned. Almost 90% of the hardwood plantations are privately owned.

The majority of the timber plantations are in KwaZulu-Natal and Mpumalanga. The distribution of softwood and hardwood plantations between provinces is shown in Figure 4.

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Figure 4. Timber plantation areas by province in 2003

Although Mpumalanga has the largest plantation area, KwaZulu-Natal pro-duces the most wood. The distribution of softwood and hardwood wood pro-duction between provinces is shown in Figure 5.


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Figure 5. Timber production by province in 2003

In total 120 000 people are employed by the industry, 60 000 in the plantations and 60 000 in the associated processing industries.

5.3.2 Forestry Biomass The biomass from timber is all the wood not suitable for commercial use that accumulates during the growing and harvesting of the timber. Sources of this residue include:

• wood from tending and thinning young stands

• waste resulting from the first commercial thinning cuttings

• logging residues from the final cutting areas

• low-quality trees with no commercial value

The amount of residue can vary significantly and depends on issues such as tree species, standing volume and tree size. Other factors affecting the quantity of residue are forest maintenance practices and harvesting techniques. Most of the residue is logging residue consisting of tree branches and crowns, unmarketable stem wood and undergrowth. This residue or foliage mass is normally ex-pressed as a percentage of the trunk mass. It is estimated that this figure is 21% for softwood and 16% for hardwood resulting in 3.13 million tons of forest bio-mass waste. A wide range of data about the composition and calorific value of this waste was found. Table 9 shows the amount of forest biomass, its composi-tion in terms of fibre, moisture and ash content and net calorific value (NCV) by wood type.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 24 Table 9. Properties of forest biomass waste

Mass Fibre Moisture Ash NCV Energy 1000 t % % % MJ/t TWh

Softwood 1 825 69.00 30.00 1.00 13 016 6.60Hardwood 1 308 69.50 30.00 0.50 11 820 4.29

Total 3 133 69.21 30.00 0.79 12 517 10.89

The net calorific values (NCV) are based on estimated gross calorific values (GCV) of fibre of 21 323 (hydrogen 6.36%) and 19 355 MJ/t (hydrogen 5.89%) for soft and hardwood respectively (www.vt.tuwien.ac.at/biobib).

KwaZulu-Natal and Mpumalanga each account for about 42% of the total waste biomass in the forest industry. The remainder is produced in the Eastern Cape, Limpopo and Western Cape (Table 10).

Table 10. Forest biomass waste by province

KZN Mpum E Cape Limpopo W Cape Gauteng 1000 t 1000 t 1000 t 1000 t 1000 t 1000 t

Softwood 524 893 217 76 115 0Hardwood 795 429 27 52 5 0

Total 1 319 1 323 244 128 120 0

Figure 6 shows the biomass energy content by wood type and province. In the calculations it is assumed that the biomass composition and calorific value is the same for each province.

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Figure 6. Energy content forest biomass waste by province in 2003

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 25 5.3.3 Forestry – Electricity Generation The total forest biomass waste is about 3.13 million tons with an energy content of 10.89 TWh. However, like with sugarcane, many agronomists see leaving some residue in the field as good practice and it might not be wise to collect the entire residue. Although no costing is carried out it is expected that the han-dling and transport of the residue is expensive and needs the development of a dedicated infrastructure. The efficiency of converting the biomass into electric-ity depends on the selected process and operating parameters. Burning the bio-mass in a conventional boiler as part of an efficient steam cycle produces 2 722 GWh at a conversion efficiency of 25% power on fuel.

5.4 Sawmill

5.4.1 Sawmill Industry There are approximately 109 sawmills in South Africa mainly in Mpumalanga and KwaZulu-Natal. In 2003 the intake of timber by the sawmill industry was about 5.58 million tons of which 93% (5.17 million ton) was softwood and 7% (0.41 million ton) hardwood.

Almost 50% of the total number of sawmills are very small with an annual wood in-take of less than 20 000 tons, 21% between 20 000 – 50 000 tons, 19% between 50 000 – 100 000 tons, 10% between 100 000 – 200 000 tons and 3% have a wood intake of over 200 000 tons.

Mpumalanga is clearly the biggest sawntimber supplier followed by KwaZulu-Natal (Figure 7).

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Figure 7. Estimated sawntimber production province in 2003

5.4.2 Sawmill Biomass In 2003 the sawmilling industry yield on softwood was about 47.6% and on hardwood 42%. This resulted in a total sawmill biomass waste of about 2.95 million tons mainly from softwood. This biomass waste consisted of 55%

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 26 chips, 28% sawdust and 17% bark. Again a wide range of data about the com-position and calorific value of this waste was found. Table 11 shows the amount of sawmill biomass, its composition in terms of fibre, moisture and ash content and net calorific value (NCV) by residue type.

Table 11. Properties of sawmill biomass waste

Mass Fibre Moisture Ash NCV Energy 1000 t % % % MJ/t TWh

Chips 1 622 59.20 40.00 0.80 10 316 4.65Dust 826 59.50 40.00 0.50 10 611 2.43Bark 501 58.00 40.00 2.00 10 135 1.41Total 2 948 59.08 40.00 0.92 10 368 8.49

The net calorific values (NCV) are based on estimated gross calorific values (GCV) of 20440 (hydrogen 6.21%), 20846 (hydrogen 6.24%) and 20431 (hy-drogen 5.80%) MJ/t for fibre in chips, dust and bark respectively (www.vt.tuwien.ac.at/biobib).

Mpumalanga is by far the biggest producer of sawmilling biomass waste with almost 49% followed by KwaZulu-Natal with 29% and the Eastern Cape with 12%. The remaining 10% is found in Limpopo and the Western Cape (Table 12).

Table 12. Sawmilling biomass waste by province


Chips 465 793 193 68 102 0Sawdust 237 404 98 34 52 0Bark 144 245 60 21 32 0

Total 846 1 443 351 123 186 0

Figure 8 shows the biomass energy content by residue type and province. In the calculations it is assumed that the biomass composition and calorific value is the same for each province.


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Figure 8. Energy content of sawmilling biomass waste by province in 2003

5.4.3 Sawmilling – Electricity Generation The total sawmilling biomass waste is about 2.95 million tons with an energy content of 8.49 TWh. At a conversion efficiency of 25% this gives about 2122 GWh of electricity. Although the power and steam requirements in the saw-milling industry are not known it is believed that this electricity will mainly be needed in-house to substitute any ESKOM power.

5.5 Pulp and paper

5.5.1 Pulp and Paper Industry In South Africa the pulp and paper industry is synonymous with Mondi and Sappi. Apart from some finishing mills, they own all the mills. Table 13 lists the nine pulp and paper mills owned by these two organisations.

Table 13. South African Pulp & Paper Mill Capacities

Company Mill Products Capacity (1000 t/a)Mondi Richards Bay Hardwood and softwood kraft pulp 576 Piet Retief Hardwood and softwood NSSC pulp 60 Felixton Unbleached bagasse pulp 70 Merebank Thermomechanical pulp 220 Goundwood pulp 66Sappi Ngodwana Hardwood and softwood kraft pulp 410 Goundwood pulp 100 Tugela Bleached softwood pulp 230 Hardwood NSSC pulp 120 Stanger Bleached bagasse pulp 60 Enstra Bleached hardwood pulp 90 Saiccor Dissolving pulp 600Total 2 602


Of the 16.86 million tons of timber produced in South Africa in 2003, 60% or about 10 million tons went to the pulp and paper industry. In addition Mondi Felixton and Sappi Stanger take in bagasse as a raw material. Table 14 gives an overview of the pulp and paper produced during 2001, 2002 and 2003.

Table 14. Production of pulp & paper in SA (1000 t)

2001 2002 2003

Printing and writing paper 863 904 916 Packaging paper 1 245 1 265 1 265 Tissue paper 150 154 152

Total paper 2 258 2 323 2 333 Total pulp 1 740 1 763 1 782 Total value (million Rand) 10 428 12 357 11 659

The above table does not include dissolving pulp, the production of which has been estimated to be 600 000 t/year.

5.5.2 Pulp and Paper - Biomass There are basically three sources of biomass produced by the pulp and paper mills namely black liquor, sludge and bark.

Black liquor: Black liquor is a residue from the chemical pulping process. This liquor is concentrated through evaporation and subsequently burnt in boilers to recover valuable process chemicals. The combustible substance is mainly lig-nin. At 50% moisture the estimated liquor quantity is over 5.2 million tons per annum.

Bark: The quantity of bark is roughly 9% of softwood pulpwood and 0.5% of hardwood pulpwood intake. This gives a total amount of bark produced by the industry in 2003 of 345 000 tons at an average moisture content of 50%.

Sludge: The quantity and quality of the sludge varies considerably and depends on mill configuration and type of paper produced. The amount of sludge also depends on its moisture content. At 50% moisture the total amount of fibre and bark sludge produced by the industry in 2003 is estimated at 234 000 tons. Sludge usually has a dry solids content of 20 to 40%. This high liquid content is often reduced by mechanical dewatering. The quantity and quality of the bio-mass residue from the pulp and paper industry is summarised in Table 15.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 29 Table 15. Properties of pulp & paper residue

Mass Fibre Moisture Ash NCV Energy1000 t % % % MJ/t TWh

Black Liq- 5206 40.00 50.00 10.00 6243 9.03Sludge 234 37.50 50.00 12.50 5777 0.38Bark 345 48.00 50.00 2.00 7975 0.76

Total 5785 40.38 50.00 9.62 6328 10.17

The net calorific values (NCV) are based on estimated gross calorific values (GCV) of fibre in black liquor and sludge of 20 000 (hydrogen 6.1%) MJ/t and a gross calorific value (GCV) of the fibre in bark of 20 431 MJ/t (hydrogen 5.80%) (www.vt.tuwien.ac.at/biobib).

The amount of biomass on a provincial basis is given in Table 16. There is no reason to believe that the properties of the biomass should be significantly dif-ferent from province to province and again they are kept the same for the dif-ferent provinces.

Table 16. Pulp & paper residue by province


Black Liquor 3 742 1 300 0 0 0 164Sludge 196 30 0 0 0 8Bark 225 120 0 0 0 0

Total 4 163 1 450 0 0 0 172

Using the net calorific values given in Table 8 and the quantities given in Table 9 the energy content of the residue can now be calculated on a provincial basis (Figure 9).


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Figure 9. Energy content of pulp and paper residues by province, 2003

5.5.3 Pulp and Paper – Electricity generation The total pulp and paper industry biomass waste is about 5.78 million tons with an energy content of 10.17 TWh. About 90% of this biomass is black liquor with an energy content of 9.03 TWh while the remainder consists of sludge and bark. Black liquor is only produced by the chemical pulping process and is usu-ally burnt to recover chemicals. The total biomass has a potential electricity capacity of about 2 542 GWh. Again the power and steam requirements in the pulp and paper industry are not very well known but they do vary from factory to factory and are vastly different between a chemical and mechanical pulping plant. Specially the paper manufacturing process requires significant amounts of heat for drying and it is believed that most of the energy will be needed in-house with little scope for export power.

5.6 Summary

Commercial biomass in South Africa is mainly produced by the sugar industry, the forest industry, the sawmilling industry and the pulp and paper industry. The majority of this biomass is found in Mpumalanga and KwaZulu-Natal with small amounts in the Eastern Cape, Limpopo, Western Cape and Gauteng.

In the sugar industry the quantity and composition of the biomass is well re-corded and the data is readily available. In the other industries quantities are often measured in volumes rather than in mass and there is particular uncer-tainty about the moisture content of the biomass. The latter has a significant effect on the net caloric value and therefore on the energy content of the bio-mass. Table 17 shows the biomass and its energy value per sector.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 31 Table 17. Biomass per sector

Industry Biomass NCV Mass Energy Power content potential MJ/t 1000 t TWh GWhe

Sugar Field residue 6 889 5 336 10.21 2 553 Bagasse 7 112 6 136 12.12 3 031

Forestry Softwood 13 016 1 825 6.60 1 650 Hardwood 11 820 1 308 4.29 1 073

Sawmill Chips 10 316 1 622 4.65 1 162 Dust 10 611 826 2.43 608 Bark 10 135 501 1.41 353

Pulp & Paper Black liquor 6 243 5 206 9.03 2 257 Sludge 5 777 234 0.38 94 Bark 7 975 345 0.76 191

Total 8 004 23 339 51.89 12 972

Not all the biomass is easily available. In the sugar industry the bagasse is al-ready at a central point at the factories but the field residue (trash and tops) is spread out over some 430 000 hectares. In the forest industry all the biomass is on the plantations covering well over 1.3 million hectares. In the sawmilling and pulp and paper industry the biomass is again at central points at the facto-ries.


6 Proposal of linking data to Homer/RE GIS

6.1 Background

6.1.1 Homer The HOMER model was developed by National Energy Renewable Labora-tory, Colorado in the United States as an optimisation model for distributed power. HOMER stands for the Hybrid Optimization Model for Electric Renew-ables. It is a computer model that simulates and optimises hybrid power sys-tems, which are stand-alone power plants that employ some combination of wind turbines, photovoltaic panels, mini-hydro systems, biomass gasifiers, or diesel generators to produce electricity. Batteries for energy storage may also be included as part of the design. Information about electrical loads (or de-mand), renewable resource potentials, and the performance and cost of various components are inputs to the model. Loads and resource potential can be time based. HOMER will then design the optimal hybrid power system to serve those loads. HOMER can model any combination of:

• wind turbines • photovoltaic panels • diesel generation • battery storage • mini hydro systems • biomass gasifiers

HOMER performs hour-by-hour performance simulations on numerous system configurations and presents the resulting information in a well-structured out-put. Possible system configurations are ranked in order of increasing cost, and the composition of each system is indicated graphically.

6.1.2 The South African Renewable Energy Resource Database CSIR developed the South African Renewable Energy Resource Database – SARERD (CSIR, 1999). The database is in the form of a number of GIS-compatible “grid layers”, with a resolution of 1km per grid cell. The database includes the biomass, solar, micro-hydro and wind renewable resources.

The biomass component of SARERD was modelled from wood, agricultural and grass residues. Residues are modelled on an annual basis and reflect ton-

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 33 nage of biomass per hectare per day. In all cases, the biomass layer reflected potential residues and not actual residues. For example, not included in the model are areas of degraded land where residues may be reduced, or current uses of wood wastes. Inclusion of an actual biomass data layer into the database is planned in a subsequent phase of SARERD.

To model the potential annual biomass component the total solar radiation needed to be estimated. The model used to estimate the total or global (i.e. di-rect plus diffuse) solar radiation is based on two components:

• the geometric model estimates solar radiation based on latitude, altitude, date, time, orientation and slope.

• the atmospheric component deals with radiation loss due to cloud cover and atmospheric constituents such as water vapour, dust, and salt crystals i.e. the 'transmissivity' of the atmosphere.

Total radiation is estimated by adjusting the predictions from the geometric model by the transmissivity predicted from the atmospheric model. Solar dura-tion and solar radiation data, collected over a 40 year period at 130 sites by the South African Weather Bureau, were used to create and verify the various components of the model. Both mean annual and monthly solar energy received per horizontal square metre (MJ/m2) have been calculated for South Africa. Figure 11 shows a typical GIS display of the resulting annual grid.

Figure 11 Mean annual solar energy received per horizontal square metre (MJ/m2) for South Africa

The major annual and biannual, non-woody, arable crops in South Africa were included in the assessment - maize, wheat, sunflowers, sugarcane, and sor-ghum. Together these crops make up over 90% of the area of arable crops

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 34 grown and over 98% of the annual production in South Africa in 1999. The model approach, for agricultural waste, has been one of using a crop yield esti-mation model to determine yield potentials. The yield estimation model uses rainfall and heat units to calculate crop tonnage. The residue for each crop, for example, husk, stalk, and leaves, is then derived from this figure as a percent-age of the tonnage. The spatial extent of the potential crop productive areas was refined with the 1996 National Land Cover Database, which records actual ar-eas under cultivation, both dry land and irrigated.

Potential wood residues were identified for processed and non-processed wood products. Non-processed products include:

• off-cuts from commercial plantation e.g. pruning • sustainable harvesting from indigenous woodlands (sustainable harvesting

is considered to be the harvesting of deadwood, not the cutting down of live trees)

• alien vegetation • deciduous tree off-cuts

Processed products included residues derived from sawmills and pulp mills, e.g. sawdust, bark, and chips. These two residues were summed together to cre-ate a final wood residue surface for South Africa.

Micro hydropower is applicable for generating power in small, rural communi-ties as, depending on the reliability of the resource, it can be economically sus-tainable. While macro hydropower reflects accumulated flow along a river, mi-cro hydropower is calculated from non-accumulated flow, in this case flow over a 1 km stretch of river. Mean monthly flows were mapped for South Af-rica using values per quaternary catchment derived from the Water Research Commission WR90 CD. Actual power potential (kW) was calculated from mean monthly flow (l/s), head (m) and acceleration due to gravity. Power po-tential has been calculated as an annual, as well as a monthly, average. Head values were calculated from the Surveyor General's 400x400m digital elevation model, by finding for each grid cell the difference between the maximum and minimum values within a 3 x 3 neighbourhood.

A wind resource atlas for South Africa was developed, which estimates mean annual wind speeds in m/s at a 10m height above ground level for approxi-mately 67% of the country. The Wind Atlas Analysis and Application Pro-gramme (WAsP) model, developed by RISO National Laboratory in Denmark, was used for the estimations of all the provinces within South Africa. The WAsP model was run for each automatic weather station with a specific extent, or modelling area, that was based on the surrounding terrain.

6.1.3 HomerGIS Subsequent to the SARERD project, a joint initiative was undertaken between the CSIR, ESKOM, the National Renewable Energy Laboratory (NREL) and the Department of Minerals and Energy (DME). The aim of the initiative was to develop an effective and efficient mechanism for extracting data from the Renewable Energy Resource Database, so that it could be processed by the HOMER model.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 35 As a result of the joint initiative, the HomerGIS tool was designed and devel-oped by CSIR (DME, 2002). HomerGIS is specifically tailored to support the assessment of how rural villages, not linked to the National Grid, could be sup-ported through alternative energy systems. The interface allows for simple “point-and-click” selection of villages; automatic execution of the HOMER model, and summarised tabular and spatial displays of the resulting outputs. A sample view of the interface is shown in Figure 12.

Figure 12 Sample Screen-shot of the HomerGIS Interface Program

6.2 Proposal to link data to HomerGIS There are two possible approaches to link data collated as part of this study to HomerGIS.

6.2.1 Option 1: Biomass Data Update The first option is to update the existing biomass grid layers and make them available for HomerGIS. Five years have passed since the work on the Renew-able Energy Resource Database (which was itself based on earlier data), and it would make sense to incorporate the new data, along with other updates that have become available.

It is strongly recommended that the HomerGIS model be upgraded so that dif-ferent biomass layers could be individually altered, without having to reprocess and consolidate all the other biomass data simultaneously. This makes sense from a number of perspectives: firstly, the data availability and frequency of updating varies for each data type (e.g. commercial agricultural information could be obtained annually, while country-wide surveys on natural biomass (e.g. grasses and uncultivated woodland) would happen less frequently. The

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 36 implication is that the original information made available for the Renewable Energy Resource Database needs to be re-examined and, if necessary, re-worked, to accommodate the proposed split in layers.

If the biomass layer is updated, another key aspect that will need to be ad-dressed is the need to make available additional spatial information about the resources that have been evaluated, either as:

• Point locations for biomass data at sites (e.g. bagasse at a sugar mill, or wood waste at a sawmill); or

• Area vectors for forestry plantations (or for residues from sugar cane fields).

It is the judgement of the SMRI research team that spatial information could indeed be found for point locations, and that the vectors for the sugar cane farms could be obtained (from SASRI). However, there is uncertainty about availability of data for the forestry plantations and this would require further investigation.

The process required to create the spatial grids for use in HomerGIS is as fol-lows:

• Collection of location data for point and area sources (existing spatial files and/ or conversion of co-ordinates into spatial entities).

• Explode the point features to polygons so that they can be merged into a general polygon layer that covers both sources of biomass.

• Addition of a spatial identifier key in the normal database tables to reflect the unique identifier of each spatial feature, so that a join between spatial and attribute data can be established.

• Generation of a shapefile/coverage that can be converted to a grid.

This process assumes that the attribute tables for point and polygon data hold the same or at least very similar data fields. At the least, a field in each table holding data about the biomass value is necessary, or else the gridding process will not be useful.

It should be noted that existing HomerGIS biomass data is not time dependant. A decision would have to be made as to which of the time-based SMRI data sets to use – alternately, some form of aggregation could be considered, or the biomass data could be presented in the same way as solar data (monthly, and aggregated annual values).

A rough estimate of the costs associated with the proposed way forward for Op-tion 1 is of the order of R100 000.

6.2.2 Option 2: Renewable Data Management Process The second option is to extend the above update within the context of a signifi-cantly more strategic approach to the whole issue of Renewable Energy Re-sources information.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 37 It is increasingly clear that effective governance and management of the natural environment requires an ongoing and well-coordinated data collection effort, supported by appropriate decision making mechanisms. Data changes both in time and space, and national resources need to be surveyed regularly, to ensure that meaningful data is updated and available to support decisions. For exam-ple, the National Census collects data every five years; data that is used in a wide variety of planning and development functions Similarly, the Depart-ment of Environment and Tourism collects information on key environmental indicators on a regular basis, and makes this information available on-line (DEAT, 2002; DEAT, 2004).

It is therefore proposed that a project be initiated that seeks to achieve the fol-lowing:

• Develop a plan of action for the ongoing management of information for renewable energy resources

• Recommend an appropriate body to carry out this management (on a permanent basis)

• Ensure that all current projects collecting data on renewable energy re-sources be effectively coordinated (to ensure consistency of approach; avoid redundant efforts, and so on)

• Collate all collected data and have it transformed, if need be, into a readily accessible format (or formats) useable by currently known tools

• Make available – preferably on-line – a national set of “best available” data sets related to renewable energy resources

A very rough estimate of the costs associated with the proposed way forward for Option 2 is of the order of R500 000. Obviously this may be increased or decreased, based on the exact Terms of Reference drawn up, and the assess-ment of the work requirements by the party (or parties) drawing up the detailed proposals.

6.3 Conclusion A decision on which of the two options presented should be chosen needs to be made by the client; based on the anticipated user needs and potential uses of renewable energy resources data. A more detailed proposal, along with tasks and costs, can then be developed.


7 Feasibility check list

7.1 Background A feasibility study should start by describing the context and reason for its preparation and the level of investigation (pre-assessment or detailed feasibil-ity). The feasibility study should address technical opportunities, identify barri-ers and evaluate potential effects as well as economics.

7.2 General Preparation of a feasibility study for an energy production plant based on bio-mass should always start by an analysis of the demand side. Usually energy demand can be reduced by various means (e.g. load shedding, reduced idle loads, condensate flashing, optimal steam bleeding, improved steam traps, vari-able speed drives, use of energy recovery, insulation etc.). Investments in the efficient use of energy are often more economical than investments in new en-ergy production capacity, i.e. always consider the rational use of energy to-gether with the supply of renewable energy.

7.3 Energy demand It is necessary to audit the energy consumption and energy costs on the demand side by analysing:

Energy bills and production data for the last three years. Tariff structure. Variations in monthly energy consumption (electricity, steam, heat, wa-

ter and throughput). Daily load patterns. Specific energy consumption (kWh/ton). It is recommended to plot

monthly readings in a diagram. Boiler efficiency tests. It is recommended to monitor daily load varia-

tions. Energy balances (process, drying, heating, evaporation, ventilation,

power use, water heating etc.) Temperature and power needs for the energy services. Compare with good practice. Ways of reducing the energy demand by various saving possibilities.

Finally investigate the potential of export of heat and power to neighbouring industry and grid.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 39 Based on this mapping of the demand side decide if there is a need for new en-ergy production equipment and how big a heat / power plant there is room for.

7.4 Biomass / Waste Resource Available The amount of biomass / waste available as fuel should be mapped, how many tonnes of each fraction is available with what morphology and moisture con-tent. Check when it is available, how it is collected, stored and transported. Is there another market for the material? What is the cost on the market? Remem-ber that cost will change if the demand increases - and that a potential profit often should be shared between the suppliers and customer. Get data on fuel characteristics such as calorific value, moisture and ash con-tent. Alkali (sodium and potassium), chloride and sulphur compounds can cause ash agglomeration, slagging or result in high temperature corrosion prob-lems in boilers etc.

7.5 Technical Evaluation The demand side determines suitable plant sizes. Describe possible technology that is mature and suitable for the fuel and purpose. Describe the logistics of how the fuel will be collected and stored. Evaluate if there is a need for pre-treatment like drying, downsizing, addition of additives etc. Normally downsiz-ing the biomass to about 50 mm is recommended and pre-drying of wet bio-mass will increase power output. If possible describe previous experience using different types of technology including references where possible. Make an overview table with the main characteristics of alternative technolo-gies and plant sizes, energy production, possible capacity regulation, need for O&M and pros & cons. Choose the preferred and possible solution as well as alternatives and continue with further economic evaluations.

7.6 Economic Evaluation List all economic pre-conditions and confirm them e.g.:

Rate of interest for calculation (typical 11-13%). Government’s inflationary targets between 3 and 6%. Economic lifespan (typically 15-20 years). Conditions of finance (normally annuity). Conditions of tax and possible support. Value of produced energy e.g. feed in tariff etc. Cost of fuel. Cost of operational personnel. Cost of ash and flue-gas residue disposal. Cost of other waste disposal.

Calculate the direct operation benefit (earnings minus expenses) for the chosen alternatives. Estimate yearly maintenance cost, these are often 1-3 % of invest-

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 40 ment costs per annum. Consider also the need for reinvestments over the total lifespan (which may be 5 years). Based on this data the break-even cost for a plant can be calculated. Normally it is now possible to judge if it is realistic to get a plant below that cost. If it looks promising quotations can be asked for from suppliers as a basis for traditional economic evaluations of alternative solutions based on calculation of e.g.:

Pay-back period (simple key figure for preliminary comparison) NPV: net present value (gives you the best financial alternative i.e.

highest value) Balanced cost of produced energy (NPV costs / NPV produced energy) IRR: internal rate of return (gives you the maximum loan interest)

Alternatively you can assume loan conditions and calculate the total extra costs of extra produced energy and compare it with what you can get from selling it to the grid. Possibility of looking at softloan – mixed credit options, which will give a 35% grant and an international finance packaged via the international export credit system (this way the loan could possibly be in Euro at 5%).

Investigate the CDM option – contact the DNA at DME and inquire about CDM options.

The DME is in the process of setting up a subsidy office to distribute subsidies to renewable energy projects in the first phase of the renewable energy strategy. Contact the DME to enquire about national subsidies.

Analyse sensitivity towards changes. Make parameter variations on selected parameters, like cost of fuel, plant efficiency, value of sold energy etc.

7.7 Environmental Conditions and Legislation Check the demands on environmental emissions. What is needed to meet these demands? Are there legislative restrictions to the location of the plant or how to dispose of ashes and flue-gas cleaning products? What documentation should be provided? How is the plant monitored and what way of self control is planned? How is operation safety and occupational health ensured for the op-eration personnel? Some relevant regulations are:

NER generation licence (for power generation above 5 MW) BEE compliance Local by-laws Standard industrial regulations (OHS Act, Labour Act) Industry specific legislation Environmental legislation (emissions to air and water) Ownership of power plant Ownership of biomass (fuel) Consultation with local communities


Figure 13. Roadmap of a feasibility Study


7.8 Case Example in the sugar industry

A typical South African sugar factory

The crushing season is eight to nine months, starting in April and finishing in November/December. The throughput in this example is 300 t/h or 1.5 million tons of cane per annum. At this throughput the boiler steam is just over 160 t/h at a pressure of 3000 kPa(a) and a temperature of 400°C. The steam is ex-panded through back pressure steam turbine prime movers and turbo alternators to 200 kPa(a). Total specific internal power requirement is 43 kWh/tc. Process steam on cane is 60% and is mainly used for multiple evaporation and juice heating. The evaporator station is a quadruple effect with vapour1 and vapour2 being used for various process duties. Cane wash water or imbibition is high at 400% on fibre resulting in an extraction of over 98%. The sugar factory is de-signed to meet its own power and steam requirements. Bagasse is used ineffi-ciently to avoid the need for a costly bagasse disposal system while minimising the burning of coal. Figure 14 shows a typical configuration for a power plant with in-house power and steam requirements.

Boiler

Condensing Turb Alternator

Prime Mover Turbine

Let Down Back Pressure Turb Alternator

Water Fuel

Steam

Steam

Blow off Process Steam

Figure 14. Typical steam and power generation with heat recovery (at present

no condensing turbo alternators are installed)

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 43 General

With a declining world sugar economy, sugar producing countries worldwide (Mauritius, Brazil, Australia and India) are turning to co-products, in particular electricity and fuel alcohol, as an additional source of income. The energy mar-ket has the advantage of being a large and growing market in which a local supplier has a comparative advantage. An industry with sugar as its only sig-nificant commercial product may no longer be sustainable.

Energy savings options on demand side

Presently the power on cane is 43 kWh/tc. This includes electric power and motive power. It should be possible to operate a raw sugar factory at levels be-low 35 kWh/tc. Wade (2004) indicates a figure of 15 kWh/tc.

The excessive use of process steam of 60% on cane is mainly due to a high im-bibition rate. Reducing imbibition decreases steam consumption but results in a loss in extraction. It is possible to reduce process steam to below 45% by a series of measures. These measures include:

• Reduce cane wash water (imbibition). • Increase number of vacuum evaporator steps. • Change to lower steam and water bleeding. • Improve steam straps. • Operate at optimum syrup brix (dry matter). • Use continuous pans. • Efficient sugar boiling scheme. • Steady operation. • Reduce pan movement water. • Optimise condensate flashing and energy recovery. • Improve housekeeping (insulation, leaks, maintenance etc.).

Biomass / Waste Resource Available

Bagasse is usually the main source of biomass in a sugar mill. It has the advan-tage that it is already at the factory. Trash and tops have the potential of dou-bling the amount of fuel and might be considered as fuel for the off crop or dur-ing stop days (Table 18). However, this residue has to be collected from the fields, which may not be practical and is prohibitively expensive. Equally im-practical and expensive is the storage of the residue. Alternatively, considera-tion can be given to the use of other biomass or even coal to maximise the use of capital equipment.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 44 Table 18. Properties of bagasse and field residue


Bagasse 450 44.00 2.00 50.00 4.00 7 117 0.89Residue 387 41.19 4.19 51.73 2.89 6 894 0.74

Total 837 42.70 3.01 50.80 3.48 7 009 1.63

Although ways of recovering trash and tops are being explored presently ba-gasse is the only practical source of biomass. It should be noted however that bagasse is sometimes used as a feed stock for other industries. These industries include pulp and paper, animal feed, particle board and furfural.

Technical evaluation

Successful use of biomass energy rests largely on the conversion system adopted. Various technologies exist such as gasification, pyrolysis, combustion and digestion. The most suitable technology can vary from biomass to biomass and region to region. Factors to consider are quality of the biomass and the cost to convert and transport the biomass. While some of the new technologies are looking promising, presently combustion technology is still the most appropri-ate and is considered here.

Most mills have spare boiler and power generating capacity. Using this spare capacity may not result in a vast production in electricity but is cheap. Another opportunity to increase power generation at a relatively low cost is by passing let down steam through backpressure turbines. Dedicated bagasse fired power stations are in operation in Reunion, Mauritius, Australia and India. These power stations operate at high steam pressures and temperatures of around 8 000 kPa(a) and 520°C respectively. Boiler efficien-cies are high at 85% and electricity is generated by extremely efficient back pressure and condensing turbo alternators with exhaust steam conditions close to saturation. Under these conditions potential capacity is about 53 MW or 197 GWh (132 kWh/tc). The total electricity available for export is 145 GWh (97 kWh/tc). Economic evaluation

The capital cost of a bagasse fired power station is estimated at ZAR 8 400/kW. In this example, an arbitrary selling price of e.g. 40 c/kWh provides additional revenue from cogeneration of approximately ZAR 58 million per annum. To put this into perspective, for the same factory, the proceeds from sugar, based on a cane to sugar ratio of 8.6 and an average price of ZAR 2100 per ton, is about ZAR 366 million per annum. Detailed analysis is necessary in each case. Environmental conditions and legislation

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 45 An independent power producer (IPP) will be subject to the usual environ-mental conditions and legislation that applies to every industrial plant. The most important additional regulation is the need for a generation licence from the National Electricity Regulator (NER). This licence is required for any ex-porter of electricity above 5 MW.

For a power station the environmental legislation governing the air and water pollution are particularly relevant. The main pollutant of a bagasse fired boiler is particulate matter. At present this particulate matter must be below 200 mg/m3 measured under standard conditions. The Sugar Act addresses legislation specific to the sugar industry. The act dic-tates amongst others the division of proceeds and the ownership of the bagasse by millers. Generation of electricity from sugarcane biomass for export purpose will no doubt reopen the debate of this ownership. Other considerations

There are other considerations one of which is ownership: ownership of the fuel and ownership of the power facility. Bagasse is owned by millers, field residue belongs to growers and additional biomass might be sourced from outside the sugar industry. This three way split in ownership of the fuel complicates the supply chain while at the same time adding flexibility. Obviously a guarantee of fuel supply both in terms of quan-tity and quality is extremely important when exporting power. The introduction of independent power producers such as sugar mills raises concern about the reliability of electricity supply. One way to deal with this concern is by placing the power facility under the control of the national power utility. This is often the case in Mauritius, Reunion and Australia.

7.9 Check List

Potential independent power producers have to consider various issues. These issues deal with energy efficiency and biomass and can be general, technical, economic or legislative in nature. Below is a list to assist potential IPP’s in pre-paring a first feasibility check. This list is non exhaustive.

General

• Background

Efficiency

• Investigate ways of reducing in-house energy requirements

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 46 Biomass

• What are the sources of biomass • Possible competition for the biomass • Availability of biomass through the year • Transport and pre-treatment of the biomass • How much biomass from each source • Quality of the biomass (water, ash and NCV) • Total energy content of biomass

Technical

• Transport and pre-treatment of the biomass • Selection of energy conversion technology • Supply of in-house energy requirements • Use spare capacity or install additional equipment • Use surplus heat for fuel drying • Connecting to the grid • Electrical system protection both ways

Financial

• Cost of electricity per kWh • Power Purchase Agreement (PPA) • Tariff structure • Various financial indices

o Internal rate of return (IRR) o Pay back period o Net present value (NPV)

• International or local financing options (e.g. mixed credits, CDM, etc.)

Legislation • General environmental conditions and legislation

o Occupational Health and Safety Act o Labour Act o National Environmental Management Act

• Legislation related to power generation and export • Industry specific legislation

Other

• Ownership of plant • Ownership of fuel • Consultation with local communities and other relevant stakeholders


8 Conclusion and Recommendations

The total amount of available biomass in the sugar, forest, sawmilling and pulp and paper industry is estimated at 23 million tons with an energy capacity of about 50 TWh. Most of this biomass is in Mpumalanga and KwaZulu-Natal. At a conversion rate of 25% power on biomass this results in an estimated electric-ity production of over 13 000 GWh.

The total biomass in the sugar industry is about 11.47 million tons with an en-ergy content of 22.33 TWh. The potential electricity that can be generated from this biomass is about 5 500 GWh. However collecting field residue might not be feasible which reduces the biomass to 6.13 million tons and 12.12 TWh. This results in a potential of 3031 GWh of electricity which is in excess of the industry’s own requirements of about 700 GWh.

Biomass in the forest industry is about 3.13 million tons with an energy content of 10.89 TWh. This translates into an electricity potential of 2723 GWh. Again collecting the biomass from the plantations might be prohibitively expensive. It needs a separate infrastructure that involves extra costs.

The sawmilling industry produces 2.95 million tons of waste biomass with an energy content of 8.49 TWh. The potential electricity from that biomass is ap-proximately 2122 GWh. However, most of this energy will be needed for inter-nal use to replace ESKOM power, leaving little opportunity for energy export.

The total pulp and paper industry biomass waste is about 5.78 million tons with an energy content of 10.17 TWh. About 90% of this biomass is black liquor with an energy content of 9.03 TWh. The biomass has a potential electricity capacity of about 2 542 GWh. Again it is believed that most of the energy will be used to meet in-house energy requirements with little left for export to the grid.

For linking the renewable energy data to the Homer/RE GIS program two pro-posals are put forward. The first proposal is to update the existing biomass grid layers and make them available for HomerGIS. The second proposal is to un-dertake a comprehensive project for the management and continuous updating of the data.

A preliminary feasibility checklist to assist potential independent power pro-ducers has been provided. It is envisaged that any future work might contribute to supplement this list.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 48 The most promising source of biomass is sugarcane bagasse. It is already being used to meet the sugar industry’s in-house steam and power requirements. In-creasing the efficient use and generation of energy within the industry can eas-ily result in a potential capacity of 3 000 GWh with in-house requirements of only 700 GWh. Based on this study and experiences in places like Mauritius, Reunion and Australia it is recommended that bagasse be targeted for the de-velopment of renewable energy projects as it is the most promising fuel source.


9 References

Anon (1995). SABS ISO 1928. Solid mineral fuels – Determination of gross calorific value by the bomb calotrific method, and calculation of the net calo-rific value. The South African Bureau of Standards, 45 pp.

Anon (2002). White paper on the promotion of renewable energy and clean en-ergy development. Part one – Promotion of renewable energy. Internal Report Department of Minerals and Energy.

Anon (2003a). Economic and Financial Calculations and Modelling for the Re-newable Energy Strategy Formulation. Internal Report Department of Miner-als and Energy.

Anon (2003b). Industry Directory. South African Sugar Association.

BIOBIB, 2004. A database for biofuels. Address: http://www.vt.tuwien.ac.at/biobib/ [Visited: 10 November 2004].

Forestry South Africa, 2004. South African Forestry Facts 2003. Address: http://www.forestry.co.za/fsa/home.do [Visited: 24 October 2004].

De Beer AG, Boast MMW and Worlock B (1989). The agricultural conse-quences of harvesting sugarcane containing various amounts of tops and trash. Proc S Afr Sug Technol Ass 63:107-110.

Wienese A (1999). Co-generation in the South African sugar industry. Proc S Afr Sug Technol Ass 73: 241-246.

Wienese A (2002). South African Sugar Factory Plant Installation 2000. SMRI Communications No 171.

Wienese A (2003). A road map for cogeneration in the South African sugar industry. SMRI Technical Report no. 1935: 11 pp.

NREL, 2004. HOMER (Hybrid Optimization Model for Electric Renewables), National Renewable Energy Laboratory. Address: http://analysis.nrel.gov/homer/ [Visited: 18 October 2004].

CSIR, 1999. South African Renewable Energy Resource Database. Ed. Jillian Muller. July 1999. CSIR Report No. ENV-P-C-98161.

http://www.vt.tuwien.ac.at/biobib/

http://www.vt.tuwien.ac.at/biobib/

http://www.forestry.co.za/fsa/home.do

http://www.forestry.co.za/fsa/home.do

http://analysis.nrel.gov/homer/

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 50 DEAT, 2002. Environmental Indicators for the National State of the Environ-ment Reporting for South Africa 2002. Department of Environmental Affairs and Tourism, Pretoria.

DEAT, 2004. National State of the Environment. Address: http://www.environment.gov.za/ [Visited: 28 October 2004].

DME, 2002. South African Renewable Energy Resource Database and Electri-fication Planning Tool (Final Report). Project No. EO0001.

Wade, 2004. Bagasse Cogeneration – Global Review & Potential. http://www.localpower.org/

http://www.deat.gov.za/


Appendix 1 – Area, Cane and Bagasse properties Table 1. Amatikulu area, cane and bagasse properties

Season Area Cane Bagasse Fibre Brix Moisture Ash NCV ha tons tons % % % % MJ/t

1994/95 38942 1271847 402597 44.47 1.56 50.07 3.90 71341995/96 39626 1318362 438044 45.54 1.34 50.15 2.97 72951996/97 39824 1925846 614800 46.85 1.55 49.07 2.53 75911997/98 40100 1663337 523457 45.15 1.52 50.12 3.21 72521998/99 40708 1728484 531797 46.41 1.42 49.89 2.29 74711999/00 38472 1655682 525923 45.77 1.55 50.47 2.21 73612000/01 38669 1844828 575052 46.83 1.79 48.94 2.44 76292001/02 39213 1624590 513791 45.99 1.94 49.86 2.21 74742002/03 38876 1672146 524964 46.64 1.80 49.29 2.27 75862003/04 38863 1160625 382569 45.42 1.84 49.79 2.95 7357

Table 2. Darnall area, cane and bagasse properties


1994/95 29562 1091691 364601 42.58 1.98 52.83 2.61 67861995/96 29672 1064052 378180 42.47 2.02 52.87 2.64 67711996/97 29874 1368524 429033 44.29 2.18 51.19 2.33 71691997/98 29084 1298974 423055 42.31 2.29 52.62 2.78 67871998/99 29805 1471318 452070 42.98 2.38 51.07 3.58 69611999/00 29843 1316241 414410 42.28 2.31 52.03 3.39 67992000/01 29387 1566072 459952 44.54 2.61 48.97 3.87 73342001/02 31328 1211236 386718 41.68 2.63 51.97 3.71 67412002/03 30733 1373582 432767 43.79 2.22 50.49 3.51 70992003/04 30789 1097397 353401 42.62 2.32 51.68 3.38 6873

Table 3. Entumeni area, cane and bagasse properties


1994/95 11418 274812 76974 46.67 1.60 49.49 2.24 75561995/96 11671 295165 86173 45.22 1.52 49.94 3.32 72681996/97 11938 376994 103032 46.28 1.79 49.31 2.62 75181997/98 11843 411120 117508 44.48 2.51 50.57 2.44 72671998/99 12559 462294 134081 42.17 2.55 52.79 2.49 67981999/00 12339 362225 105672 43.03 2.39 52.01 2.56 69502000/01 12468 402220 119987 44.33 2.40 51.21 2.06 72072001/02 12645 405585 123001 43.19 2.23 51.62 2.96 69652002/03 12822 409394 123700 42.87 1.93 51.34 3.86 68662003/04 12932 361203 113145 42.79 2.09 51.96 3.16 6861


Table 4. Eston area, cane and bagasse properties


1994/95 0 0 0 0.00 0.00 0.00 0.00 01995/96 0 0 0 0.00 0.00 0.00 0.00 01996/97 23947 932640 315019 39.15 2.47 52.49 5.89 62421997/98 26680 1082425 356049 39.26 1.89 51.89 6.96 61881998/99 26211 1429666 402937 41.81 2.19 50.68 5.32 67291999/00 26590 1038443 293288 43.79 1.61 50.56 4.04 70062000/01 31822 1336913 404687 42.51 1.90 50.58 5.01 68162001/02 33572 1255166 395871 41.68 2.00 51.12 5.21 66652002/03 34234 1418128 438414 43.12 1.92 50.38 4.57 69362003/04 35100 1307274 399768 43.62 2.10 49.70 4.58 7070

Table 5. Felixton area, cane and bagasse properties


1994/95 36947 1619122 572752 41.81 1.48 52.36 4.35 65811995/96 37792 1945215 707039 40.57 1.53 52.94 4.97 63471996/97 36680 2657958 940230 40.68 1.68 53.67 3.97 63731997/98 38073 2637644 896887 42.00 1.53 52.00 4.46 66321998/99 37805 2175156 695046 42.89 1.59 51.97 3.55 68031999/00 38773 2264777 768034 42.37 1.58 52.05 4.00 67062000/01 37865 2573257 840533 42.89 1.94 50.98 4.19 68812001/02 38115 2018564 681754 41.08 2.09 52.64 4.18 65342002/03 38439 2175081 753309 41.25 1.86 53.37 3.51 65122003/04 37824 1894726 683138 41.42 1.85 53.35 3.38 6541

Table 6. Gledhow area, cane and bagasse properties


1994/95 35306 1434249 460648 44.73 1.58 50.29 3.40 71791995/96 36300 1322562 445015 43.50 1.44 50.90 4.16 69191996/97 35741 1776818 579604 43.15 1.71 51.16 3.97 68901997/98 35561 1766386 554688 43.21 1.68 50.81 4.29 69041998/99 34352 1587143 482568 43.00 2.71 50.71 3.58 70241999/00 30193 1357981 410947 45.43 2.34 49.84 2.39 74342000/01 29817 1490845 437945 46.50 1.97 48.43 3.10 76072001/02 29523 1150711 346102 47.06 1.82 48.40 2.72 76872002/03 30102 1383225 399067 47.80 1.94 47.62 2.63 78612003/04 28391 1175622 361946 46.30 1.90 49.50 2.30 7534


Table 7. Komati area, cane and bagasse properties


1994/95 9546 441375 122257 46.99 1.36 46.63 5.02 76471995/96 10894 705376 184358 47.54 1.54 46.45 4.47 77811996/97 12812 905463 243638 49.30 1.60 45.00 4.11 81451997/98 15207 1415923 420650 48.27 1.84 45.32 4.57 79861998/99 16967 1411946 385175 48.54 1.99 45.31 4.16 80591999/00 18330 1815360 470540 49.28 1.52 45.81 3.39 81102000/01 19272 2013230 534230 46.60 1.77 47.25 4.38 76242001/02 20097 1907090 495583 48.98 1.82 46.53 2.66 80852002/03 22736 2056787 522658 47.80 1.89 46.00 4.31 78912003/04 23976 2137724 529150 49.63 2.20 46.28 1.89 8266

Table 8. Malelane area, cane and bagasse properties


1994/95 16323 990304 316172 40.44 1.75 54.30 3.51 63231995/96 17313 880841 273275 42.72 1.89 51.68 3.71 68251996/97 18177 1293927 418968 40.75 1.63 53.40 4.22 63851997/98 18012 1614449 528109 40.31 1.70 53.53 4.46 63121998/99 19461 1706003 555288 40.85 1.49 53.04 4.61 63911999/00 19996 1717679 553273 41.85 1.19 52.63 4.33 65372000/01 21331 1810312 603259 40.74 1.82 51.97 5.47 64462001/02 22005 1761160 597211 40.79 1.74 53.08 4.38 64172002/03 21796 1853104 572082 43.01 1.76 51.89 3.35 68532003/04 22698 1837756 534868 42.52 1.87 52.26 3.35 6772

Table 9. Maidstone area, cane and bagasse properties


1994/95 47378 1870056 625256 43.44 1.75 53.26 1.54 68981995/96 48632 1685273 651427 39.18 1.18 56.34 3.30 59581996/97 48521 1832811 648992 40.54 1.52 55.02 2.92 62901997/98 47739 2149047 749553 39.60 1.59 55.77 3.04 61101998/99 45821 2077934 692850 42.82 1.24 54.22 1.71 66851999/00 45641 1679182 542752 44.27 0.97 52.58 2.18 69472000/01 40694 2166647 699695 45.23 1.44 51.25 2.08 72262001/02 39354 1648747 559059 43.87 1.30 52.55 2.28 69262002/03 36079 1899923 619662 44.03 1.36 51.74 2.87 69832003/04 35599 1389215 465187 43.06 1.29 51.87 3.77 6793


Table 10. Noodsberg area, cane and bagasse properties


1994/95 30181 1108230 308580 46.55 2.23 48.42 2.80 76561995/96 30533 1276372 389917 42.69 2.65 51.07 3.59 69501996/97 31376 1357536 405664 42.67 2.05 51.51 3.78 68441997/98 31809 1388436 397829 43.73 2.19 50.46 3.62 70851998/99 32188 1723301 475928 44.73 2.41 50.55 2.31 72991999/00 31971 1273609 348065 44.97 2.40 50.31 2.33 73462000/01 32055 1396476 388019 44.15 2.25 50.49 3.12 71692001/02 31569 1565601 439540 42.26 2.36 51.69 3.69 68132002/03 31935 1673982 472056 42.74 2.21 51.12 3.93 68922003/04 31782 1614763 470914 44.03 2.29 49.88 3.80 7170

Table 11. Pongola area, cane and bagasse properties


1994/95 13821 1173815 346402 45.62 1.76 49.22 3.40 73951995/96 14472 992495 301075 42.16 1.89 50.09 5.85 67631996/97 15428 1047475 295384 45.82 1.70 47.79 4.69 74571997/98 16753 1276122 381291 44.32 1.87 48.27 5.54 71981998/99 17217 1185726 347195 44.04 2.06 49.65 4.24 71431999/00 17156 1275712 357789 42.10 2.31 50.26 5.32 68122000/01 17476 1242290 365708 42.41 2.20 49.43 5.96 68702001/02 17198 1355654 390795 42.31 2.18 49.12 6.39 68572002/03 18170 1409293 391920 43.58 2.24 49.21 4.97 70952003/04 18337 1426568 400000 42.63 2.22 50.89 4.26 6878

Table 12. Sezela area, cane and bagasse properties


1994/95 39305 1898876 620717 44.86 1.67 49.12 4.35 72461995/96 41239 2291244 737961 45.08 1.28 48.75 4.88 72361996/97 42363 2312766 711633 44.48 1.88 48.67 4.97 72201997/98 40872 2173070 679284 45.06 1.72 47.68 5.54 73251998/99 43981 2524887 755281 45.51 1.86 48.30 4.33 74131999/00 44300 2265266 693809 45.85 1.89 48.88 3.39 74642000/01 44996 2490169 777991 46.44 1.67 48.11 3.78 75582001/02 45933 2187376 692227 46.76 1.58 47.98 3.68 76062002/03 45323 2321365 723192 48.35 1.56 47.18 2.92 79122003/04 43248 2014283 628673 47.70 1.62 47.65 3.03 7792


Table 13. Umfolozi area, cane and bagasse properties


1994/95 17039 1000150 303049 42.15 2.24 51.45 4.16 67801995/96 17313 1140328 326811 43.16 2.20 49.95 4.70 69941996/97 18562 1185275 368493 40.93 2.68 51.28 5.11 66281997/98 18649 1263950 383457 42.39 2.21 50.59 4.82 68391998/99 19873 1225284 375381 41.02 2.28 51.43 5.27 65811999/00 20425 1321990 399254 41.50 2.06 51.87 4.56 66252000/01 19930 1388824 412899 42.21 2.37 50.35 5.07 68382001/02 20565 1172173 343007 42.42 2.02 50.90 4.66 68102002/03 21865 1262294 359957 43.49 2.12 50.28 4.11 70342003/04 22105 1087606 307435 42.76 2.19 49.91 5.13 6922

Table 14. Umzimkulu area, cane and bagasse properties


1994/95 26490 856994 302464 42.71 1.45 52.69 3.15 67331995/96 26299 1149505 392596 40.39 1.65 53.08 4.88 63301996/97 27834 1313252 429502 40.93 1.68 52.00 5.40 64581997/98 28451 1218833 389965 42.52 1.76 51.02 4.69 67861998/99 29432 1389799 444678 42.01 1.73 52.55 3.71 66511999/00 29404 1170533 359096 44.08 1.52 50.96 3.44 70362000/01 29558 1436380 440801 44.52 1.73 50.08 3.67 71692001/02 29841 1148041 369545 43.28 1.85 50.92 3.96 69392002/03 29664 1299759 397357 44.82 1.79 49.38 4.00 72512003/04 29440 1136866 353819 45.30 1.62 49.70 3.38 7305

Table 15. Union Co-op area, cane and bagasse properties


1994/95 17041 651769 204266 40.10 1.81 54.67 3.42 62621995/96 18565 646857 205176 39.01 1.86 55.32 3.81 60551996/97 19036 663550 191833 41.21 1.80 54.12 2.87 64771997/98 19703 795065 238911 41.16 2.15 53.83 2.86 65281998/99 21266 831383 242100 41.34 2.10 54.00 2.57 65481999/00 21011 708409 220831 41.60 2.10 53.87 2.43 65992000/01 21258 717705 235907 40.84 1.98 53.87 3.32 64412001/02 21820 744868 253738 38.98 1.91 56.19 2.92 60352002/03 21734 804492 241162 41.66 1.89 53.69 2.76 65842003/04 21702 777306 235840 42.91 1.86 52.49 2.74 6836


Appendix 2 – Cane and Bagasse properties 2003/04 Season Table 1. Amatikulu cane and bagasse properties 2003/04 season

Season Month Cane Bagasse Fibre Brix Moisture Ash NCV tons tons % % % % MJ/t2003/04 Mar 0 0 0.00 0.00 0.00 0.00 182602003/04 Apr 14212 5036 43.86 2.18 53.95 0.00 70232003/04 May 159494 50535 45.68 1.90 50.36 2.07 73992003/04 Jun 170629 54351 44.84 1.86 50.08 3.21 72472003/04 Jul 234726 74650 44.28 1.77 50.23 3.73 71272003/04 Aug 171270 56682 46.89 1.78 49.46 1.87 76242003/04 Sep 160008 53976 46.57 1.91 48.78 2.75 76012003/04 Oct 199413 69550 45.25 1.87 49.50 3.38 73382003/04 Nov 50873 17789 44.15 1.77 49.50 4.59 71202003/04 Dec 0 0 0.00 0.00 0.00 0.00 18260

Table 2. Darnall area, cane and bagasse properties


Table 3. Entumeni area, cane and bagasse properties



Table 4. Eston area, cane and bagasse properties


Table 5. Felixton area, cane and bagasse properties


Table 6. Gledhow area, cane and bagasse properties



Table 7. Komati area, cane and bagasse properties


Table 8. Malelane area, cane and bagasse properties


Table 9. Maidstone area, cane and bagasse properties



Table 10. Noodsberg area, cane and bagasse properties


Table 11. Pongola area, cane and bagasse properties


Table 12. Sezela area, cane and bagasse properties



Table 13. Umfolozi area, cane and bagasse properties


Table 14. Umzimkulu area, cane and bagasse properties


Table 15. Union Co-op area, cane and bagasse properties



Appendix 3 – Power generation potential Table 1. Amatikulu power generation potential

Local Export Total Local Export Total Local Export TotalMW MW MW kWh/t kWh/t kWh/t GWh GWh GWh

1994/95 12.02 36.08 48.11 35.00 105.07 140.07 44.51 133.63 178.151995/96 12.37 41.09 53.45 35.00 116.27 151.27 46.14 153.29 199.441996/97 13.57 45.06 58.63 35.00 116.25 151.25 67.40 223.87 291.281997/98 13.36 40.74 54.10 35.00 106.69 141.69 58.22 177.45 235.671998/99 12.44 38.30 50.74 35.00 107.78 142.78 60.50 186.30 246.801999/00 12.46 39.34 51.80 35.00 110.47 145.47 57.95 182.90 240.852000/01 12.69 41.03 53.72 35.00 113.16 148.16 64.57 208.76 273.332001/02 12.83 41.12 53.95 35.00 112.21 147.21 56.86 182.29 239.152002/03 12.12 39.27 51.38 35.00 113.41 148.41 58.53 189.65 248.172003/04 10.88 36.16 47.04 35.00 116.36 151.36 40.62 135.05 175.68

Table 2. Darnall power generation potential


1994/95 9.89 29.85 39.75 35.00 105.60 140.60 38.21 115.29 153.501995/96 9.69 31.86 41.55 35.00 115.10 150.10 37.24 122.47 159.711996/97 10.37 30.92 41.29 35.00 104.33 139.33 47.90 142.78 190.681997/98 10.73 31.22 41.96 35.00 101.83 136.83 45.46 132.28 177.741998/99 11.18 30.98 42.17 35.00 96.98 131.98 51.50 142.69 194.191999/00 10.74 29.80 40.54 35.00 97.10 132.10 46.07 127.81 173.882000/01 11.28 31.59 42.88 35.00 98.00 133.00 54.81 153.47 208.282001/02 10.69 29.90 40.59 35.00 97.89 132.89 42.39 118.57 160.962002/03 10.76 31.86 42.62 35.00 103.59 138.59 48.08 142.29 190.362003/04 10.22 29.78 39.99 35.00 102.02 137.02 38.41 111.96 150.37

Table 3. Entumeni power generation potential


1994/95 2.60 7.09 9.69 35.00 95.46 130.46 9.62 26.23 35.851995/96 2.66 7.29 9.96 35.00 95.83 130.83 10.33 28.29 38.621996/97 2.86 7.46 10.32 35.00 91.28 126.28 13.19 34.41 47.611997/98 3.24 8.58 11.82 35.00 92.81 127.81 14.39 38.15 52.541998/99 3.35 8.20 11.55 35.00 85.66 120.66 16.18 39.60 55.781999/00 3.03 7.74 10.76 35.00 89.45 124.45 12.68 32.40 45.082000/01 3.10 8.66 11.76 35.00 97.73 132.73 14.08 39.31 53.392001/02 3.12 8.49 11.61 35.00 95.18 130.18 14.20 38.60 52.802002/03 3.12 8.25 11.36 35.00 92.64 127.64 14.33 37.93 52.252003/04 3.01 8.39 11.40 35.00 97.68 132.68 12.64 35.28 47.92


Table 4. Eston power generation potential


1994/95 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001995/96 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001996/97 6.75 18.31 25.06 35.00 94.91 129.91 32.64 88.51 121.151997/98 7.73 19.88 27.62 35.00 89.99 124.99 37.88 97.40 135.291998/99 8.98 20.66 29.64 35.00 80.57 115.57 50.04 115.19 165.231999/00 8.06 19.83 27.89 35.00 86.14 121.14 36.35 89.45 125.802000/01 8.53 22.37 30.90 35.00 91.86 126.86 46.79 122.80 169.602001/02 8.18 22.07 30.24 35.00 94.49 129.49 43.93 118.59 162.532002/03 8.79 24.45 33.24 35.00 97.34 132.34 49.63 138.04 187.672003/04 8.49 23.90 32.39 35.00 98.54 133.54 45.75 128.82 174.57

Table 5. Felixton power generation potential


1994/95 15.46 48.48 63.94 35.00 109.78 144.78 56.67 177.76 234.421995/96 17.11 52.96 70.07 35.00 108.35 143.35 68.08 210.77 278.851996/97 19.86 59.45 79.31 35.00 104.79 139.79 93.03 278.53 371.561997/98 19.62 58.78 78.39 35.00 104.86 139.86 92.32 276.57 368.891998/99 18.81 53.38 72.19 35.00 99.36 134.36 76.13 216.11 292.241999/00 18.63 56.48 75.10 35.00 106.13 141.13 79.27 240.36 319.632000/01 19.20 57.25 76.45 35.00 104.35 139.35 90.06 268.51 358.572001/02 17.86 51.85 69.72 35.00 101.58 136.58 70.65 205.05 275.702002/03 17.88 53.59 71.47 35.00 104.86 139.86 76.13 228.09 304.222003/04 18.58 59.36 77.94 35.00 111.84 146.84 66.32 211.92 278.23

Table 6. Gledhow power generation potential


1994/95 11.01 27.65 38.66 40.00 100.43 140.43 57.37 144.04 201.411995/96 11.43 29.12 40.55 40.00 101.93 141.93 52.90 134.81 187.721996/97 11.13 26.84 37.97 40.00 96.49 136.49 71.07 171.45 242.521997/98 11.50 26.20 37.70 40.00 91.11 131.11 70.66 160.94 231.591998/99 11.92 26.49 38.41 40.00 88.91 128.91 63.49 141.11 204.601999/00 10.86 26.23 37.08 40.00 96.63 136.63 54.32 131.22 185.542000/01 11.59 27.71 39.31 40.00 95.61 135.61 59.63 142.54 202.172001/02 10.67 26.91 37.58 40.00 100.86 140.86 46.03 116.06 162.092002/03 11.05 27.03 38.08 40.00 97.86 137.86 55.33 135.37 190.702003/04 10.21 25.87 36.08 40.00 101.36 141.36 47.02 119.16 166.18


Table 7. Komati power generation potential


1994/95 5.16 14.10 19.26 35.00 95.58 130.58 15.45 42.19 57.641995/96 6.13 15.74 21.87 35.00 89.86 124.86 24.69 63.38 88.071996/97 7.53 21.62 29.15 35.00 100.56 135.56 31.69 91.05 122.741997/98 8.48 27.33 35.81 35.00 112.80 147.80 49.56 159.71 209.271998/99 8.81 25.41 34.22 35.00 101.01 136.01 49.42 142.62 192.041999/00 13.79 37.22 51.01 35.00 94.49 129.49 63.54 171.54 235.072000/01 14.78 37.65 52.44 35.00 89.15 124.15 70.46 179.48 249.942001/02 14.55 39.23 53.78 35.00 94.41 129.41 66.75 180.04 246.792002/03 14.74 37.03 51.77 35.00 87.93 122.93 71.99 180.85 252.842003/04 14.19 36.79 50.98 35.00 90.71 125.71 74.82 193.90 268.72

Table 8. Malelane power generation potential


1994/95 11.14 22.57 33.71 40.00 81.00 121.00 39.61 80.21 119.831995/96 8.76 19.21 27.97 40.00 87.68 127.68 35.23 77.23 112.461996/97 12.37 26.06 38.43 40.00 84.29 124.29 51.76 109.06 160.821997/98 12.74 26.78 39.52 40.00 84.12 124.12 64.58 135.80 200.381998/99 12.68 26.99 39.66 40.00 85.17 125.17 68.24 145.30 213.541999/00 13.37 29.04 42.40 40.00 86.88 126.88 68.71 149.23 217.942000/01 13.02 29.22 42.25 40.00 89.75 129.75 72.41 162.47 234.882001/02 13.02 29.82 42.83 40.00 91.64 131.64 70.45 161.39 231.842002/03 13.71 30.01 43.72 40.00 87.55 127.55 74.12 162.24 236.362003/04 12.38 24.07 36.45 40.00 77.75 117.75 73.51 142.89 216.40

Table 9. Maidstone power generation potential


1994/95 12.47 41.77 54.24 35.00 117.20 152.20 65.45 219.18 284.631995/96 13.44 41.50 54.94 35.00 108.09 143.09 58.98 182.16 241.141996/97 15.40 45.31 60.71 35.00 102.96 137.96 64.15 188.70 252.851997/98 15.73 43.36 59.09 35.00 96.46 131.46 75.22 207.29 282.511998/99 14.66 43.18 57.84 35.00 103.07 138.07 72.73 214.17 286.901999/00 14.01 41.71 55.73 35.00 104.19 139.19 58.77 174.95 233.722000/01 14.90 46.89 61.79 35.00 110.17 145.17 75.83 238.70 314.532001/02 13.55 43.04 56.59 35.00 111.16 146.16 57.71 183.28 240.992002/03 13.27 40.32 53.58 35.00 106.36 141.36 66.50 202.08 268.582003/04 11.59 35.16 46.75 35.00 106.17 141.17 48.62 147.50 196.12


Table 10. Noodsberg power generation potential


1994/95 11.04 24.47 35.50 40.00 88.66 128.66 44.33 98.25 142.581995/96 11.39 25.08 36.47 40.00 88.08 128.08 51.05 112.42 163.471996/97 11.34 23.47 34.82 40.00 82.78 122.78 54.30 112.38 166.681997/98 11.44 23.39 34.83 40.00 81.76 121.76 55.54 113.52 169.061998/99 11.54 23.32 34.86 40.00 80.79 120.79 68.93 139.23 208.161999/00 11.25 22.56 33.81 40.00 80.24 120.24 50.94 102.19 153.132000/01 11.65 23.05 34.70 40.00 79.18 119.18 55.86 110.57 166.432001/02 12.15 22.42 34.57 40.00 73.81 113.81 62.62 115.56 178.192002/03 11.88 22.55 34.43 40.00 75.90 115.90 66.96 127.06 194.022003/04 11.31 24.28 35.58 40.00 85.88 125.88 64.59 138.68 203.27

Table 11. Pongola power generation potential


1994/95 8.08 18.60 26.68 40.00 92.07 132.07 46.95 108.07 155.031995/96 8.06 16.78 24.84 40.00 83.22 123.22 39.70 82.60 122.301996/97 8.66 18.76 27.42 40.00 86.69 126.69 41.90 90.81 132.711997/98 8.98 20.18 29.16 40.00 89.93 129.93 51.04 114.76 165.811998/99 9.33 20.04 29.37 40.00 85.92 125.92 47.43 101.88 149.311999/00 9.55 17.59 27.13 40.00 73.66 113.66 51.03 93.97 145.002000/01 9.97 20.24 30.21 40.00 81.25 121.25 49.69 100.93 150.622001/02 9.97 19.47 29.44 40.00 78.15 118.15 54.23 105.95 160.172002/03 10.16 19.78 29.94 40.00 77.91 117.91 56.37 109.80 166.182003/04 10.05 18.82 28.87 40.00 74.90 114.90 57.06 106.85 163.91

Table 12. Sezela power generation potential


1994/95 13.78 44.32 58.10 35.00 112.53 147.53 66.46 213.68 280.141995/96 14.57 45.76 60.33 35.00 109.97 144.97 80.19 251.96 332.151996/97 14.52 42.54 57.06 35.00 102.57 137.57 80.95 237.22 318.171997/98 14.88 45.58 60.46 35.00 107.18 142.18 76.06 232.92 308.981998/99 15.57 45.49 61.06 35.00 102.30 137.30 88.37 258.29 346.661999/00 14.87 45.43 60.29 35.00 106.94 141.94 79.28 242.26 321.542000/01 14.64 46.87 61.51 35.00 112.04 147.04 87.16 279.01 366.162001/02 14.95 49.17 64.12 35.00 115.14 150.14 76.56 251.86 328.412002/03 14.82 50.42 65.24 35.00 119.06 154.06 81.25 276.38 357.622003/04 13.84 46.20 60.04 35.00 116.82 151.82 70.50 235.31 305.81


Table 13. Umfolozi power generation potential


1994/95 9.94 20.72 30.66 40.00 83.40 123.40 40.01 83.41 123.421995/96 9.88 19.76 29.64 40.00 80.02 120.02 45.61 91.25 136.861996/97 10.00 20.96 30.97 40.00 83.83 123.83 47.41 99.36 146.771997/98 10.22 21.67 31.89 40.00 84.80 124.80 50.56 107.18 157.741998/99 11.45 23.13 34.57 40.00 80.82 120.82 49.01 99.03 148.041999/00 11.47 22.88 34.36 40.00 79.79 119.79 52.88 105.48 158.362000/01 11.00 22.54 33.54 40.00 81.95 121.95 55.55 113.81 169.372001/02 10.29 20.38 30.67 40.00 79.23 119.23 46.89 92.87 139.762002/03 10.43 20.89 31.32 40.00 80.13 120.13 50.49 101.14 151.642003/04 9.96 19.12 29.08 40.00 76.80 116.80 43.50 83.53 127.03

Table 14. Umzimkulu power generation potential


1994/95 7.37 23.81 31.19 35.00 113.05 148.05 29.99 96.88 126.881995/96 7.91 22.27 30.18 35.00 98.54 133.54 40.23 113.27 153.511996/97 8.22 22.35 30.57 35.00 95.17 130.17 45.96 124.98 170.941997/98 8.62 24.44 33.06 35.00 99.17 134.17 42.66 120.87 163.531998/99 8.91 24.50 33.41 35.00 96.24 131.24 48.64 133.76 182.401999/00 8.14 22.86 31.00 35.00 98.30 133.30 40.97 115.07 156.042000/01 8.38 24.21 32.59 35.00 101.12 136.12 50.27 145.25 195.522001/02 8.49 25.07 33.56 35.00 103.40 138.40 40.18 118.71 158.892002/03 9.00 26.30 35.30 35.00 102.25 137.25 45.49 132.90 178.392003/04 8.74 26.50 35.25 35.00 106.09 141.09 39.79 120.61 160.40

Table 15. Union Co-op power generation potential


1994/95 4.72 11.47 16.19 35.00 85.03 120.03 22.81 55.42 78.231995/96 4.74 11.13 15.87 35.00 82.20 117.20 22.64 53.17 75.811996/97 4.84 10.93 15.77 35.00 78.96 113.96 23.22 52.39 75.621997/98 5.15 12.51 17.67 35.00 84.98 119.98 27.83 67.56 95.391998/99 5.05 11.72 16.76 35.00 81.26 116.26 29.10 67.56 96.661999/00 4.77 12.45 17.22 35.00 91.44 126.44 24.79 64.78 89.572000/01 4.74 12.94 17.68 35.00 95.51 130.51 25.12 68.55 93.672001/02 4.69 12.24 16.93 35.00 91.37 126.37 26.07 68.06 94.132002/03 4.95 12.12 17.07 35.00 85.79 120.79 28.16 69.02 97.182003/04 4.75 12.57 17.32 35.00 92.60 127.60 27.21 71.98 99.19


Appendix 4 – Sugar mill Questionnaire General

1 2 Name of interviewee 3 Position of interviewee 4 Date

Cane throughput

1 Cane supply area (hectares) 2 Cane crushed per annum (tons/annum) 3 Gross available time (hours) 4 Overall time efficiency (%)

Bagasse throughput and properties

1 Bagasse produced per annum ( / )2 Fibre content of bagasse (%)

3 Brix content of bagasse (%) 4 Moisture content of bagasse (%) 5 Ash content of bagasse (%) 6 Net calorific value of bagasse (kJ/kg)

Steam and power generation.

1 Existing boiler capacity (t/h) 2 High pressure steam pressure (kPa(abs)) 3 High pressure steam temperature (°C) 4 Existing power generation capacity (kW) 5 Exhaust steam pressure (kPa(abs)) 6 High Pressure steam production (t/h) 7 Process steam requirements (t/h) 8 Process power requirements (kW) 9 Let down steam (t/h)

Biomass, steam and power export

1 Bagasse export (t/h) 2 Steam export (t/h) 3 Power export (kW)

Obstacles for co-generation

1 2 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 67 Tongaat Hulett - Amatikulu

General 1 Company name Hulett - Amatikulu 2 Name of interviewee D M Van Den Berg 3 Position of interviewee Regional Operations Manager 4 Date 21/9/2004

Cane throughput

1 Cane supply area (hectares) 51 7912 Cane crushed per annum (tons/annum) 1 750 0003 Gross available time (hours) 5 0194 Overall time efficiency (%) 83


1 Bagasse produced per annum ( / )

280 0002 Fibre content of bagasse (%) 48.53 Brix content of bagasse (%) 1,754 Moisture content of bagasse (%) 49,55 Ash content of bagasse (%) 2,656 Net calorific value of bagasse (kJ/kg) 7 425


1 Existing boiler capacity (t/h) 2332 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 370 (388)4 Existing power generation capacity (kW) 12 0005 Exhaust steam pressure (kPa(abs)) 1406 High Pressure steam production (t/h) 2257 Process steam requirements (t/h) 1458 Process power requirements (kW) 8 7509 Let down steam (t/h) 35


1 Bagasse export (t/h) Fibre to sappi 150002 Steam export (t/h) 03 Power export (kW)can do 2500 kW 1000


1 Price paid is too low and more lucrative to export Fibre 2 Eskom a major stumbling block to deal with re pricing 3 Current price in SA in U$2 per kW/h, Brazil is U$20 per kW/h

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 68 Tongaat Hulett - Darnall

General 1 Company name Hulett - Darnall 2 Name of interviewee Nigel Simmonds 3 Position of interviewee Engineering Manager 4 Date

Cane throughput

1 Cane supply area (hectares) 291502 Cane crushed per annum (tons/annum) 1 350 0003 Gross available time (hours) 5 0284 Overall time efficiency (%) 82



447 4922 Fibre content of bagasse (%) 453 Brix content of bagasse (%) 1.14 Moisture content of bagasse (%) 51,85 Ash content of bagasse (%) 2.66 Net calorific value of bagasse (kJ/kg) 6 873


1 Existing boiler capacity (t/h) 2802 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 3804 Existing power generation capacity (kW) 120005 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 1857 Process steam requirements (t/h) 1808 Process power requirements (kW) 55009 Let down steam (t/h) 30


1 Bagasse export (t/h) BDF 15000 TONS AVERAGE 2 Steam export (t/h) 0 3 Power export (kW) 0


1 Can not synchronise with Eskom 2 Obviously no protection between Eskom and ourselves 3 Sell Fibre to Sappi so price plays an important role

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 69 Tongaat Hulett - Entumeni

General 1 Company name Hulett - Entumeni 2 Name of interviewee A Wienese 3 Position of interviewee Head Engineering SMRI 4 Date 20 August 2004

Cane throughput

1 Cane supply area (hectares) 12 9322 Cane crushed per annum (tons/annum) 361 2033 Gross available time (hours) 5 5014 Overall time efficiency (%) 76



113 1452 Fibre content of bagasse (%) 45,953 Brix content of bagasse (%) 2,094 Moisture content of bagasse (%) 51,965 Ash content of bagasse (%) 3,166 Net calorific value of bagasse (kJ/kg) 6 861


1 Existing boiler capacity (t/h) 21 (46)2 High pressure steam pressure (kPa(abs)) 2 600 (1 800)3 High pressure steam temperature (°C) 370 (330)4 Existing power generation capacity (kW) 1 000 (3 000)5 Exhaust steam pressure (kPa(abs)) 1806 High Pressure steam production (t/h) 7 Process steam requirements (t/h) 8 Process power requirements (kW) 9 Let down steam (t/h)


1 Bagasse export (t/h) 2 Steam export (t/h) 3 Power export (kW)


1 2 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 70 Illovo - Eston

General 1 Company name Illovo - Eston 2 Name of interviewee B Holmes 3 Position of interviewee Factory Manager 4 Date 21/09/04

Cane throughput






1 Existing boiler capacity (t/h) 1602 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 4004 Existing power generation capacity (kW) 8 5005 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 1347 Process steam requirements (t/h) 1458 Process power requirements (kW) 127509 Let down steam (t/h) 43


1 Bagasse export (t/h) 02 Steam export (t/h) 03 Power export (kW) 0


1 2 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 71 Tongaat Hulett - Felixton

General 1 Company name Hulett - Felixton 2 Name of interviewee J.de Jager 3 Position of interviewee Eng. Manager 4 Date 20 Sep. 04

Cane throughput






1 Existing boiler capacity (t/h) 4502 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 4004 Existing power generation capacity (kW) 31 5005 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) Up to 2907 Process steam requirements (t/h) Up to 1158 Process power requirements (kW) Up to 210009 Let down steam (t/h) Up to 90


1 Bagasse export (t/h) 1602 Steam export (t/h) 03 Power export (kW) Not exporting at present (5MW capacity)


1 Not economical (Eskom pricing)

2 Intertripping protection not adequate 3 System connection limitations

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 72 uShukela - Gledhow

General 1 Company name Ushukela Milling 2 Name of interviewee Eckard Lucht 3 Position of interviewee Factory Manager 4 Date 22/09/04

Cane throughput






1 Existing boiler capacity (t/h) 2342 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 390 (370)4 Existing power generation capacity (kW) 13 6505 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 1557 Process steam requirements (t/h) 1558 Process power requirements (kW) 8 0009 Let down steam (t/h) 5




1 Presently all fibre exported of which 60% is returned as pith for fuel. 2 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 73 Transvaal Sugar - Komati

General 1 Company name TSB - Komati 2 Name of interviewee G M Rolfe 3 Position of interviewee Komati Mill – General Manager 4 Date 20th September 2004

Cane throughput






1 Existing boiler capacity (t/h) 2202 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 4104 Existing power generation capacity (kW) 20 0005 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 2107 Process steam requirements (t/h) 2308 Process power requirements (kW) 14 0009 Let down steam (t/h) 105


1 Bagasse export (t/h) 92 Steam export (t/h) 18.753 Power export (kW) 2 500


1 Regulatory framework for Renewable Energy not in place (Market rules) 2 Renewable Energy Targets not mandatory – Limited RE market 3 Network access and wheeling cost

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 74 Transvaal Sugar - Malelane

General 1 Company name TSB - Malelane 2 Name of interviewee Franco Weyers 3 Position of interviewee Factory Manager 4 Date 21 September 2004

Cane throughput






1 Existing boiler capacity (t/h) 4422 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 4004 Existing power generation capacity (kW) 32 4005 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 2047 Process steam requirements (t/h) 2108 Process power requirements (kW) 12 0009 Let down steam (t/h) 15


1 Bagasse export (t/h) 62 0002 Steam export (t/h) 03 Power export (kW) 2 500


1 Low tariff / income from co-generation 2 Eskom network stability – risk to plant 3 Capital outlay required to upgrade export systems

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 75 Tongaat Hulett - Maidstone

General 1 Company name Hulett - Maidstone 2 Name of interviewee Stuart Watson 3 Position of interviewee Engineering Manager 4 Date

Cane throughput

1 Cane supply area (hectares) 35 5992 Cane crushed per annum (tons/annum) 1 420 0003 Gross available time (hours) 48904 Overall time efficiency (%) 85



442000

2 Fibre content of bagasse (%) 46,833 Brix content of bagasse (%) 1,294 Moisture content of bagasse (%) 51,005 Ash content of bagasse (%) 3.776 Net calorific value of bagasse (kJ/kg) 6 793


1 Existing boiler capacity (t/h) 370 (25)2 High pressure steam pressure (kPa(abs)) 3 200 (1 500)3 High pressure steam temperature (°C) 400 (280)4 Existing power generation capacity (kW) 22 500 (6 000)5 Exhaust steam pressure (kPa(abs)) 200 (1 500)6 High Pressure steam production (t/h) 2507 Process steam requirements (t/h) 2008 Process power requirements (kW) 125009 Let down steam (t/h) Reduced to min levels – focus on co-gen


1 Bagasse export (t/h) 75-1002 Steam export (t/h) 15 – 20

3 Power export (kW) 5000 Obstacles for co-generation

1 Available MW on the Maidstone Major Bus- bar. 2 Factory constraints ito steam usage 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 76 Illovo - Noodsberg

General 1 Company name Illovo – Noodsberg 2 Name of interviewee Johan Jansen van Rensburg 3 Position of interviewee Engineering Manager 4 Date 20 September 2004

Cane throughput




470 9142 Fibre content of bagasse (%) 47,833 Brix content of bagasse (%) 2,294 Moisture content of bagasse (%) 50.25 Ash content of bagasse (%) 3,806 Net calorific value of bagasse (kJ/kg) 7 170


1 Existing boiler capacity (t/h) 1902 High pressure steam pressure (kPa(abs)) 3 2003 High pressure steam temperature (°C) 4004 Existing power generation capacity (kW) 17 0005 Exhaust steam pressure (kPa(abs)) 2206 High Pressure steam production (t/h) 1607 Process steam requirements (t/h) 150

8 Process power requirements (kW) 16 5009 Let down steam (t/h) 35




1 Due to the refinery shortfall of bagasse made up by coal 2 Electrical consumption very high and most of the power consumed by mill

3 3 X Old boilers very inefficient and con not be operated on a continuous basis – de-ashed 1 boiler every week

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 77 Illovo - Pongola

General

1 Company name Illovo - Pongola 2 Name of interviewee John Hulley 3 Position of interviewee Factory Manager 4 Date 26/10/2004

Cane throughput






1 Existing boiler capacity (t/h) 140 (46)2 High pressure steam pressure (kPa(abs)) 3 200 (1 800)3 High pressure steam temperature (°C) 400 (260)4 Existing power generation capacity (kW) 10 000 (1 500)5 Exhaust steam pressure (kPa(abs)) 2006 High Pressure steam production (t/h) 127 (18 )7 Process steam requirements (t/h) 1457 Process power requirements (kW) 7.2 mw elect power plus 3.9 mw steam 8 Let down steam (t/h) 8 tons/hr to 700 kpa range and 10 tons/hr

h Biomass, steam and power export

1 Bagasse export (t/h) None

2 Steam export (t/h) None 3 Power export (kW) 1 mw to village and effluent plant


1 Low fibre % cane at start of season, resulting in coal firing. Profitability of Co Gen ? 2 T.A. set installed capacity wrt. reliability of 1.5 mw set 3 Currently little or no letdown margin when running 1.5 mw T.A. with two 5 mw sets

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 78 Illovo - Sezela

General 1 Company name Illovo - Sezela 2 Name of interviewee Vis Pillay 3 Position of interviewee Factory Manager 4 Date 23 September 2004

Cane throughput

1 Cane supply area (hectares) 423842 Cane crushed per annum (tons/annum) 2 014 2833 Gross available time (hours) 5 7624 Overall time efficiency (%) 88





1 Existing boiler capacity (t/h) 360 (100)2 High pressure steam pressure (kPa(abs)) 3 200 (2 200)3 High pressure steam temperature (°C) 390 (330)4 Existing power generation capacity (kW) 19 0005 Exhaust steam pressure (kPa(abs)) 2106 High Pressure steam production (t/h) 3207 Process steam requirements (t/h) 2408 Process power requirements (kW) 10 0009 Let down steam (t/h) 15

Biomass, steam and power export ( supplied to Downstream plant )

1 Bagasse export (t/h) 95% of total bagasse sent to DS plant 2 Steam export (t/h) 150tph 2100kpa and 75tph return of

150k3 Power export (kW) nil Obstacles for co-generation

1 No available bagasse, burning coal for DS steam requirement 2 Alternator low power factor 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 79 Illovo - Umfolozi

General 1 Company name Illovo - Umfolozi2 Name of interviewee Morne Bester3 Position of interviewee Plant Engineer, Front End and Boilers4 Date 28-9-2004

Cane throughput






1 Existing boiler capacity (t/h) 220 (rated at MCR of boilers)2 High pressure steam pressure (kPa(abs)) 3 200 3 High pressure steam temperature (°C) 400 (bagasse firing),360 (coal firing)

4 Existing power generation capacity (kW) 14 0005 Exhaust steam pressure (kPa(abs)) 2106 High Pressure steam production (t/h) 140 t/h (at average crush rate of 300 tch) 7 Process steam requirements (t/h) 140 t/h (at average crush rate of 300 tch)8 Process power requirements (kW) 10 MW (Tot Plant),5 MW (RawH & Ref)9 Let down steam (t/h) 60 t/h (at average crush rate of 300 tch)


1 Bagasse export (t/h) None2 Steam export (t/h) None3 Power export (kW) None


1 Unstable Firing Conditions in Boilers 2 ESKOM HT reticulation in a bad state 3 Not enough installed electrical generating capacity

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 80 Illovo - Umzimkulu

General 1 Company name Illovo - Umzimkulu 2 Name of interviewee Lal Bachan

3 Position of interviewee Factory Manager 4 Date 27/09/2004

Cane throughput






1 Existing boiler capacity (t/h) 130 (72)2 High pressure steam pressure (kPa(abs)) 3 200 (1 800)3 High pressure steam temperature (°C) 400 (260)4 Existing power generation capacity (kW) 3 750 (5 500)5 Exhaust steam pressure (kPa(abs)) 2106 High Pressure steam production (t/h) Approx 1507 Process steam requirements (t/h) Approx 1558 Process power requirements (kW) +- 5 0009 Let down steam (t/h) +- 70


1 Bagasse export (t/h) nil2 Steam export (t/h) nil3 Power export (kW) nil


1 The price that Eskom is prepared to pay for electricity is too low 2 Capital costs are high 3

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 81 Union Co-op

General 1 Company name Union Co-op 2 Name of interviewee Karl Schröder 3 Position of interviewee Engineering Manager 4 Date 22 September 2004

Cane throughput

1 Cane supply area (hectares) 21 7022 Cane crushed per annum (tons/annum) 777 3063 Gross available time (hours) 6 7634 Overall time efficiency (%) 85





1 Existing boiler capacity (t/h) 1652 High pressure steam pressure (kPa(abs)) 2 0003 High pressure steam temperature (°C) 2824 Existing power generation capacity (kW) 4 5005 Exhaust steam pressure (kPa(abs)) 1706 High Pressure steam production (t/h) See attached Word Document7 Process steam requirements (t/h) Approx. 908 Process power requirements (kW) Approx. 3 5009 Let down steam (t/h) Approx. 17.5


1 Bagasse export (t/h) Approx. 3 2 Steam export (t/h) Approx. 28 4263 Power export (kW) 1 000 from beginning of Sep. to end of

M Obstacles for co-generation

1 2 3


Appendix 5 – Sawmill Questionnaire

General 1 Sawmill name and location

2 Details of interviewee

3 Position of interviewee Roundwood log intake, sawntimber production and plant operating time, 2004

solid-m3 t

1 Softwood log intake Hardwood log intake

2 Sawn timber output (total), Of which output of dried timber

3 Number of operating days / year Number of operating days / week Number of operating hours / day

Wood processing waste production volumes, 2004

solid-m3 t (as received)

1

Chips (total production volume) - own use in energy production (%) - sales outside (%)

- landfilling or other use (%)

2

Sawdust (total production volume) - own use in energy production (%) - sales outside (%)


3

Bark (total production volume) - own use in energy production (%) - sales outside (%)


Wood processing waste properties

Chips Sawdust Bark

1 Moisture content, fresh waste (%)

2 Ash content in dry matter (%)

3 Net calorific value, fresh waste (kJ/kg)

4 Net calorific value in dry matter (kJ/kg)

5 Bulk density as received (kg/loose-m3)

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 83 Steam and power generation

1

Existing boiler (main boiler): - capacity (t/h) - age (years) - boiler type (e.g. grate) - fuels used (e.g. 50% coal, 50% bark)

2 High pressure steam pressure (kPa(abs))

3 High pressure steam temperature (°C)

4 Existing power generation capacity (kW)

5 Exhaust steam pressure (kPa(abs))

6 Process steam requirements (t/h)

7 Process power requirements (kW)

8 Let down steam (t/h) Steam and power export

2 Steam export (t/h)

3 Power export (kW) Obstacles for co-generation (to invest to modernization or to new co-generation plant)

1

2

3 Interest of the company to study possibilities to utilize process waste in energy production

1 Are there existing studies made ?

2


Appendix 6 – Pulp and Paper Questionnaire

General 1 Paper mill name and location

2 Details of interviewee

3 Position of interviewee

4 Date Roundwood log intake, pulp ,waste paper,filler and plant operating time

1 Softwood log intake (t/a) Hardwood log intake (t/a)

2 Chemical pulp (softwood) (t/a)

3 Chemical pulp (hardwood) (t/a)

4 Waste paper (t/a)

5 Filler (t/a)

6 Operating days / year

Pulping output (t/a)

1 Bleached Kraft (softwood)

2 Bleached Kraft (hardwood)

3 Deinked and/or screened waste paper pulp

4 TMP/GWD

5 NSCC

6 Other Paper output (t/a).

1 Printing and writing grade papers

2 Packaging grade papers

3 Tissue

4 Other


- boiler type (e.g. grate)


1

Existing boiler (main boiler): - capacity (t/h) - age (years)

- fuels used (e.g. 50% coal, 50% bark)







8 Let down steam (t/h)

Waste material (t/a)

1

Bark (total production volume) (t/a) - own use in energy production (%) - sales outside (%)


2

Sludge (t/a) own use in energy production (%)

- landfilling or other use (%) -moisture (%) -ash content (%)


1

2

3

4


1 Have studies been made?

2


Mondi – Piet Retief Date: 07/09/2004

General

1 Company name & Milll name and location

Mondi, Piet Retief Mill, Vroegeveld farm, Ermelo road, Piet Retief

2 Name of interviewee Johan Viviers

3 Position of interviewee Technical Manager

4 Operating days 365 Roundwood log intake, pulp ,waste paper,filler and plant operating time

1 Softwood log intake (t/a) Hardwood log intake (t/a) SW chips 90 000 HW logs 70 000

2 Chemical pulp (softwood) (t/a)

3 Chemical pulp (hardwood) (t/a) 55 000

4 Waste paper (t/a) 70 000

5 Filler (t/a) 0

6 Operating days / year 365


1 Bleached Kraft (softwood)

2 Bleached Kraft (hardwood)

3 Deinked and/or screened waste paper pulp 63 000

4 TMP/GWD

5 NSCC

6 Other 12 000 bought in pulp Paper output (t/a).


2 Packaging grade papers 130 000

3 Tissue

4 Other

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 87 Steam and power generation.

1


(1) 26 (2) 26 (3) 16 (4) 12 grate type 100% coal

2 High pressure steam pressure (kPa(abs)) (1) 30 bar (2) 30 bar (3) 10 bar (4) 15 bar

3 High pressure steam temperature (°C) (1) 400 (2) 400 (3) 186 (4) 220

4 Existing power generation capacity (kW) 7.9 MW

5 Exhaust steam pressure (kPa(abs)) 340 kPa

6 Process steam requirements (t/h) 52

7 Process power requirements (kW) 16 MW

8 Let down steam (t/h) Waste material (t/a)

1



0

2



0

Obstacles for co-generation 1 Burning waste pulp containing plaxtics will cause an environmental problem.

2 No heat recovery possible from Copeland because the heat is already used.

3 Burning bark will cause heavy metal problem in the ash that must be disposed of which will required an upgrade to solid waste site specifications.

4


1 Have studies been made?

2


Sappi– Saiccor Date: 19/08/2004

General


Sappi Saiccor

2 Name of interviewee Derek Airey

3 Position of interviewee Environmentalist


1 Softwood log intake (t/a) Hardwood log intake (t/a) 2 000 000

2 Chemical pulp (softwood) (t/a) -

3 Chemical pulp (hardwood) (t/a) -

4 Waste paper (t/a) -

5 Filler (t/a) -



1 Bleached Kraft (softwood) -

2 Bleached Kraft (hardwood) -

3 Deinked and/or screened waste paper pulp -

4 TMP/GWD -

5 NSCC -

6 Other: Chemical Cellulose 600 000 Paper output (t/a).

1 Printing and writing grade papers -

2 Packaging grade papers -

3 Tissue -

4 Other -


- age (years)


1

Existing boiler (main boiler): - capacity (t/h)

- boiler type (e.g. grate) - fuels used (e.g. 50% coal, 50% bark)

MgO Recovery 6 Coal Boilers 180 t/h 240 t/h 20 yrs 30 – 50 yrs

- grate + spreader liquor coal

2 High pressure steam pressure (kPa(abs)) 8 500 4 500

3 High pressure steam temperature (°C) 490 450

4 Existing power generation capacity (kW) 28 000 18 000

5 Exhaust steam pressure (kPa(abs)) 500 kPa

6 Process steam requirements (t/h) 380

7 Process power requirements (kW) 70

8 Let down steam (t/h) - Waste material (t/a)

1



-

2



-

Obstacles for co-generation 1 Process steam demand / non-condensing sets

2

3

4


1 Have studies been made? Yes

2


Sappi– Stanger Date: 23/10/2004

General


Sappi Stanger

2 Name of interviewee Stephen Trickett

3 Position of interviewee Senior Project Engineer


1 Softwood log intake (t/a) Hardwood log intake (t/a) 0 t/a

2 Chemical pulp (softwood) (t/a) 25000

3 Chemical pulp (hardwood) (t/a) 2000

4 Waste paper (t/a) 500

5 Filler (t/a) 8600

6 Bagasse (t/a) 56000



1 Bleached Kraft (softwood) 0 t/a

2 Bleached Kraft (hardwood) 0 t/a

3 Deinked and/or screened waste paper pulp 0 t/a

4 TMP/GWD 0 t/a

5 NSCC 0 t/a

6 Other 57,000 ADTPA Bagasse Pulp Soda Cook Paper output (t/a).

1 Printing and writing grade papers 75000

2 Packaging grade papers 0 t/a

3 Tissue 29000

4 Other 19000 Soda Ash Byproduct


1


4x boilers. 2x 32t/h & 2x 28t/h 25 years on site but bought 2nd hand Chain Grate A Grade Coal

2 High pressure steam pressure (kPa(abs)) 21,000 kPa

3 High pressure steam temperature (°C) 350 deg C

4 Existing power generation capacity (kW) 0 kW

5 Exhaust steam pressure (kPa(abs)) 305

6 Process steam requirements (t/h) 75 to 85 t/h

7 Process power requirements (kW) 14000 MWH average per month

8 Let down steam (t/h) Item 6 less 19 tons Waste material (t/a)

1



0 t/a

2



4 to 12 t/d Landfilling 100% Ash content?

3 Sugar Cane Pith 55 to 70 BDTPD at 80% moisture content

4 Soda Ash (Na2Co3) from black cooking liquor Sold


1 Capital

2 Economies of scale 3 4 5

Interest of the company to study possibilities to utilize process waste in energy production

1 Have studies been made? Yes. Installation of 8 t/hr low pressure boiler fuelled by waste (pith and sludge). Insufficient payback on R20m of capital.

2

SASAQ Project to use black liquor in modern gasification technology to generate steam and recover chemicals. Element of pulp capacity debottlenecking. Capital R485m with insufficient payback. In conjunction we also looked at cogeneration. Capital for small scale operation exces-sive ±R600m


Mondi – Richards Bay Date: 11/08/2004

General


Mondi Richards Bay

2 Name of interviewee Ciska Terblanche

3 Position of interviewee Environmental Manager

4 Operating days Roundwood log intake, pulp ,waste paper,filler and plant operating time


410.000 T/a 1.88 m t/a

2 Chemical pulp (softwood) (t/a) -

3 Chemical pulp (hardwood) (t/a) -

4 Waste paper (t/a)

5 Filler (t/a)

6 Bagasse (t/a)



1 Bleached Kraft (softwood) Unbleached – 130 000

2 Bleached Kraft (hardwood) 590 000 ad/a

3 Deinked and/or screened waste paper pulp -

4 TMP/GWD -

5 NSCC -

6 Other - Paper output (t/a).


2 Packaging grade papers 230.000

3 Tissue

4 Other Steam and power generation.

1 Existing boiler (main boiler): - capacity (t/h) - age (years)

Recovery 1 80 kg/s 2 32 kg/s

3 x PB – 20 kg/s

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 93 - boiler type (e.g. grate) - fuels used (e.g. 50% coal, 50% bark)



4 Existing power generation capacity (kW) 0.88 mwh/t


6 Process steam requirements (t/h) 9.1 t/adt

7 Process power requirements (kW) 1.28 mwh/t


1



300 t/d (wet) 100%

2



120 t/month (dry) Felixton 12-25-35 calcium carb.

Total = wet (t) x dry content Wet = total dry 120 = 272 t/d Dry cont. 0.44


1

2

3

4


1

2 600 t/d capacity of boiler.

Assessment of Commercially Exploitable Biomass Resources: Bagasse, Wood & Sawmill Waste and Pulp, in South Africa 94 Sappi– Ngodwana

Date: 11/08/2004

General


Sappi Ngodwana Mill

2 Name of interviewee Kobus Geldenhuys

3 Position of interviewee Pulp Sales Manager

4 Operating days 24 hours all year round Roundwood log intake, pulp ,waste paper,filler and plant operating time


1.6 million tons softwood and 0.3 million ton hardwood

2 Chemical pulp (softwood) (t/a) Nil

3 Chemical pulp (hardwood) (t/a) Nil

4 Waste paper (t/a) + 40 000 tons

5 Filler (t/a) + 8 000 tons



1 Bleached Kraft (softwood) 200,000 tpa

2 Bleached Kraft (hardwood) 25,000 tpa

3 Deinked and/or screened waste paper pulp 36,000 tpa

4 TMP/GWD 100 000 tpa

5 NSCC Nil

6 Other 200,000 tpa unbleached pulp Paper output (t/a).

1 Printing and writing grade papers Nil

2 Packaging grade papers 250,000 tpa liner board

3 Tissue Nil

4 Other Steam and power generation.

1










1



Production 120,000 tpa Own use 50,000 tons Sales 70,000 tons Nil as from Sept 2004

2



Production 84,000 tpa Nil as from Sept 04 85% moisture


1

2

3

4


1 Have studies been made? Not that I’m aware of.

2

As can be seen from the above we will convert all bark and fibre sludge into compost as from September 2004. It took us years to get this so far, but in doing this we will re-duce our landfill by 50% and extend the life of the landfill. The real cost savings come in the long term because the whole process of expanding the landfill sites is delayed. The abovementioned volumes are estimated numbers and this info should not be used in any publications, it is merely info to better understand the situation at the mill. Techni-cal data from the mill is not available at this point in time and we would expect the DME to inform us of their intention to do a survey and your involvement in the project.


Sappi– Tugela Date: 11/08/20054

General

1 Company name & Milll name and location Sappi Tugela

2 Name of interviewee Kobus Geldenhuys

3 Position of interviewee Pulp Sales Manager

4 Operating days 24 hours all year Roundwood log intake, pulp ,waste paper,filler and plant operating time


0.9 million tons softwood and 0.4 million ton hardwood

2 Chemical pulp (softwood) (t/a) Nil

3 Chemical pulp (hardwood) (t/a) Nil

4 Waste paper (t/a) + 75,000 tons

5 Filler (t/a) + 10,000 tons



1 Bleached Kraft (softwood) Nil

2 Bleached Kraft (hardwood) Nil

3 Deinked and/or screened waste paper pulp 60,000 tpa

4 TMP/GWD Nil

5 NSCC 120,000 tpa

6 Other 220,000 tpa unbleached pine pulp Paper output (t/a).

1 Printing and writing grade papers Nil

2 Packaging grade papers 400,000 tpa liner board

3 Tissue Nil

4 Other


1









1



Production 70,000 tpa Own use nil tons Sales 70,000 tons Nil

2



Production 60,000 tpa Nil to landfill Mixed with bark for composting 85% moisture


1 2 3 4 5

Interest of the company to study possibilities to utilize process waste in energy production

1 Have studies been made? Not that I’m aware of.

2

As can be seen from the above we will convert all bark and fibre sludge into compost as from September 2004. It took us years to get this so far, but in doing this we will re-duce our landfill by 55% and extend the life of the landfill. The real cost savings come in the long term because the whole process of expanding the landfill sites is delayed. The abovementioned volumes are estimated numbers and this info should not be used in any publications, it is merely info to better understand the situation at the mill. Techni-cal data from the mill is not available at this point in time and we would expect the DME to inform us of their intention to do a survey and your involvement in the project.



Appendix 7 – Terms of Reference

DEPARTMENT OF MINERALS AND ENERGY DME-Danida Capacity Building in Energy Efficiency & Renewable Energy

Terms of Reference

Title of Assignment:

Assessment of commercially exploitable bio-mass resources: bagasse, wood and sawmill waste and pulp, in South Africa

Approved by Project Director, DME

Consultants(s): Approved by Counterpart, DME

Counterparts: Mr Andre Otto, Deputy Director, DME

Approved by CTA, COWI

Time frame: 100 days during the period 01 July 2004 to 30 November 2004.

Budget Line: Special Project Project Number: P-54126

1 Background

The Department of Minerals and Energy (DME), South Africa is responsible for formulating strategies and drafting legislation for the South African energy sector.

As a result of a dialogue between the DME and Danced over the years 1999 to 2001 the Project "Capac-ity Building in DME in Energy Efficiency (EE) and Renewable Energy (RE) (CaBEERE), has been formulated.

The CaBEERE Project aims at enhancing DME´s capacity and performance by assisting in developing programmatic approaches through strategies and actions plans for energy efficiency and renewable en-ergy in transparent co-operation with relevant stakeholders. The project aims at making the DME a "learning organisation" better able to update, develop and implement strategies and action plans within EE and RE. The project approach is primarily built on learning by doing through on the job training of DME staff and other stakeholders. At the end of the project DME will be able to effectively and effi-ciently meet its energy efficiency and renewable energy mandate as prescribed by the White Paper on Energy Policy and to sustain this capacity.

These ToR relates to the exploitation of commercially based biomass resources for electricity genera-tion. According to a macro economic study on utilising renewable energy resources in South Africa, electricity production based on commercially based biomass is among the most cost effective for renew-able energy applications. Assuming a least-cost approach for implementation of renewable energy ap-plications, a major contribution to the RE target can be derived from commercially available biomass resources. Detailed data on biomass resources (bagasse, pulp and forest wood waste and sawmill wood waste), energy content and physical/chemical characteristics are presently not available. This informa-tion is needed to determine the actual potential of power generation from biomass and to establish a reli-able basis to enable possible IPP’s to carry out due diligence studies as part of possible project prepara-tions.

.


2 Overall objective of the CaBEERE Project

Increased use of renewable energy and energy efficiency throughout South Africa to maximise the en-ergy sector's contribution towards sustainable development.

3 Immediate Objectives

3.1 Immediate objective of the CaBEERE Project

DME and relevant stakeholders are resourced and capacitated to formulate and facilitate implementation of strategies and legislation promoting energy efficiency and renewable energy production and use in both rural and urban areas.

3.2 Immediate objectives of these Terms of Reference

Commercially exploitable biomass resources (bagasse, wood and sawmill waste and pulp) are identified for electricity generation. The identification includes data on the quantity and locality of the resources, the characteristics of the biomass including the energy content of the resources and ownership of these resources. The objective is also to develop a guideline for technical and economical evaluation of spe-cific project proposals.

4 Output of these terms of reference

4.1 Data on the quantity of the various types of commercially based biomass resources (bagasse, wood waste, sawmill waste and pulp) available for energy generation in various regions in South Africa

4.2 Overview of the industry producing these resources. This would include information such as ownership, industry size and other economic indicators.

4.3 Biomass characteristics such as moisture content, calorific content and wood classification (shape/size etc.) per sector.

4.4 The handling , storage and transportation of these materials and impact on final costs.

4.5 Proposal regarding linkage of data to the Homer/Re GIS developed by CSIR/DME/Eskom. It will then be the responsibility of the DME to drive this process forward.

4.6 A feasibility check list to assist potential IPP’s

4.7 To conduct a workshop with relevant stakeholders for each of the three sectors ie. Bagasse, wood and sawmill waste and pulp).

4.8 Publish feasibility check list to ensure that relevant stakeholders have access to the information.

4.9

.


a) Identification of industries/persons to be selected for conducting interviews. Representatives from large and medium size companies in the different sectors are visited (sugar industry, sawmill, forest in-dustry and paper industry). Questionnaires are prepared before the visits are performed. The number of planned visits are:

• Treatment of biomass waste and the uses thereof.

e) Develop a biomass feasibility checklist

5 Scope of Work

The scope of works includes but is not necessary limited to:

• visit to 5 large scale industries in each of the sectors: sugar industry, forest industry, saw mill and paper industries, totally 20 visits

• visit to 5 medium scale industries in each of the sectors: sugar industry, forest industry, saw mill and paper industries, totally 20 visits

The planned visits will be approved by DME.

b) Data collection

Key data on the production and availability of the different types of biomass is collected, including:

• Average annual production of biomass at the different sectors per province • Annual variations in the production • Processes for collecting the resources and storage thereof

c) Characteristics for biomass resources

In order to know the energy content of the biomass and the costs for possible processing/storage of the biomass before it can be utilised for energy generation, a number of physical and chemical characteris-tics shall be determined. This includes:

• Energy content • Moisture content • Classification of biomass waste according to shape and size

d) Proposal on incorporating data into Homer/RE GIS database

The collected data needs to be fed into the Homer/RE GIS, which was developed by DME/Eskom/CSIR. A proposal will be needed to detail the activities surrounding this task. The DME will be tasked with ensuring that this proposal is implemented.

Key data and other information are required in order to evaluate the technical and economical feasibility of possible biomass projects. This data will be used to compile a check list for evaluation purposes to assist IPP’s when selecting potentially viable options for renewable energy projects. The DME will be

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6.1 Methodology

tasked with the dissemination of the feasibility checklist and it is envisaged that it will be published on the DME/CaBEERE website.

f) Workshops

The consultant will conduct a workshop with relevant stakeholders for each of the three sectors. The consultant will drive this process in close consultation and interaction with the DME and Local Renew-able Energy Adviser. The workshop participants will be decided by both the consultant and DME/CaBEERE personnel. The cost associated with the workshop (i.e venue, catering etc.) shall be borne by the consultant. The consultant will be tasked with inviting the participants and managing the workshop database and responses thereof.

g) Publish Feasibility check List

The Local Renewable Energy Adviser will ensure that the relevant stakeholders have access to the fea-sibility check list by ensuring that it gets published on the DME/CaBEERE website.

6 Methodology and Time Frames

The collection of the data and information is made via direct visits to relevant industries and is based on a questionnaire approach. After the first visit a review of the prepared questionnaire is made and revi-sions are made if necessary.

Existing parameters used for describing the various types of biomass are reviewed. If necessary addi-tional parameters are identified in order to describe the biomass from an energy resource point of view. Proposed standards for measuring the parameters shall be specified.

6.2 Time schedule

The consultant will be responsible for delivery of the tasks as described in these terms of reference.

The consultant will treat all information with confidentiality and only reproduce or speak about work outside the project with the prior knowledge of the DME and CaBEERE. The consultant will further sign a declaration of confidentiality.

This project shall be completed within a period of 5 months starting from the date of contract signing. The consultant shall during the project period prepare progress reports in order to monitor the achieve-ment of the objectives.

The total amount of working days cannot be exceeded without the prior approval of CaBEERE.

The time schedule and the milestones for the project are indicated in the table below.

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Milestone Dead line after date of contract signing

Contract signing between SP and DME/COWI

Inception meeting including consultants proposal on detailed time schedule and methodology

Week 1

Draft questionnaire prepared by the consultant submitted to the project team for approval

Week 2

Progress meeting Week 4

Completion of data collection Week 8


Completion of characteristics for biomass resources Week 10

Complete proposal incorporating data into Homer/RE GIS database

Week 10


Compile feasibility check list Week 12

Workshops completed with all relevant stakeholders for each of the sectors

Week 16


Draft report submitted to project team for comments Week 18

Final report submitted to project team Week 20

7 Counterparts and resources

The Counterpart will be DME. A project team will be established to assist with all issues related to the project. The consultant is responsible for the supply of sufficient resources to complete the study. The consultant may obtain support from DME in connection with identification of relevant contact persons and/or identification of reports etc.

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• Knowledge of the Electricity and Renewable Energy sector in South Africa

[email protected]

It is envisaged that the successful consulting team will consist of the following key expertise:

• Thorough knowledge of the sugar/bagasse sector, the pulp and paper sector and sawmill/timber sector in South Africa and documented experience (national/international) of work done in these three sectors.

• Documented experience in terms of conducting feasibility studies in the abovementioned sec-tors.

• Documented evidence of conducting and arranging workshops

• Linkages with other national/international consultants is encouraged, to obtain the right project team composition.

Daily DME and Project Counterpart:

Andre Otto, Deputy- Director (DME)

Kumesh Naidoo – Local Renew-able Energy Advisor

Phone number: (012) 317 9225

Phone number: (012) 317 9597

[email protected]

8 Reporting

At the inception meeting the consultant shall present the methodology to be utilised and the detailed time schedule for the visits.

The final report of the study shall include a description of the applied methodology, companies visited, results of the visits, presentation of the collected data and information as well as a presentation of the proposed data base structure.

An outline of the main headings in the report are:

1. Introduction

2. Methodology

3. Visited companies/persons

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•

4. Biomass resources and their characteristics 4.1 Bagasse 4.2 Wood waste 4.3 Sawmill waste 4.4 Pulp and paper

5. Proposal of linking data to Homer/RE GIS.

6. Feasibility checklist.

The draft and final reports shall be submitted in one original and six copies. An electronic version will also be required.

CaBEERE will supply a standard report format for the purposes of compiling the report.

9 List of Material

• Energy White Paper 1998, DME

• Renewable Energy White Paper 2003, DME

Economic and Financial Calculations and Modelling for the Renewable Energy Strategy Formu-lation, DME/Danida 2004.

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Appendix 8 – Contacts in Biomass Forest Industry Name Organisation Position Phone Cell E-mail

Mike Chetty Inst. Commercial Forestry Research (033) 3862314 [email protected] Patrick Kime NCT Forest General Manager (033) 8978500 [email protected] Peter Keyworth NCT Forest General Manager Special Projects (033) 8978522 082 8028950 [email protected]

Mike Edwards Forestry South Africa Executive Director [email protected] Roger Godsmark Forestry South Africa Assistant Director (011) 8033403 [email protected]

Schalk Kapp Global Forest Products 082 8886524 [email protected] Lorraine McNamara Global Forest Products Silviculture and Technology Manager 082 8986238 [email protected]

Shaun McCartney Global Forest Products Environmental Manager 083 6274188 [email protected]

Sawmilling Industry Name Organisation Position Phone Cell E-mail

Ian Perry Crickmay & Associates Director (031) 5084354 [email protected]

Hans Merensky – Singisi Production Manager (039) 553 0504 [email protected]

Gert Kruger Hans Merensky – Tweefontein Despatch Superintendent (013) 764 1251 gertk@ hansmerensky.co.za

Sarvaas Nieuwoudt Graskop Sawmill Owner/Manager (013) 764 2158 [email protected]

Jeffroy Hawkes Global Forest Products - Sabie Chief Engineer (013) 764 1649 [email protected]

Anthony Wilson Global Forest Products Product Co-ordinator (013) 764 9122 082 8026226 [email protected]

Faan Struweg

al Report Biomass.doc .

Pulp and Paper Industry Name Organisation Position Phone Cell E-mail

Stefan Eriksson Jaakko Poyry South Africa Manager-Process Section (031) 2500381 082 5550407 [email protected]

Iain Kerr Paper Manufacturers Ass of SA Senior Research Fellow (031) 2602186 082 8794748 [email protected]

John Hunt Paper Manufactures Ass of SA Executive Director 082 8936230 [email protected] Kobus Geldenhuys Sappi - Ngodwana Sales Manager (013) 7346192 083 6616398 [email protected] Shane Ramcour Sappi - Tugela SHEQ Manager (032) 456 1111

Derek Airey Sappi - Saiccor Environmentalist (039) 973 8911 [email protected] Stephen Walker Sappi - Enstra Safety Manager (011) 360 0000 Stephen Trickett Sappi - Stanger Senior Project Engineer (032) 437 2212 [email protected] Ciska Terblanche Mondi – Richards Bay Environmental Manager (035) 9022322 [email protected] Theo van Rooyen Mondi - Merebank Technical Manager (032) 451 2111 Johan Viviers Mondi – Piet Retief Technical Manager (032) 451 2111 [email protected]


Sugar Industry Name Organisation Position Phone Cell E-mail

Arnoud Wienese Sugar Milling Research Institute Head Engineering Division (031) 2731356 083 718 8294 [email protected]

Stephen Walford Sugar Milling Research Institute Senior Research Officer (031) 2731377 [email protected]

Adrian Wynne SA Cane Growers Liaison Manager (031) 5087200 083 457 8208 [email protected]

Denis Tomlinson Illovo Sugar Corp. Affairs Development Manager (031) 5084442 [email protected]

Graham Mann Illovo - Noodsberg General Manager (033) 5011650 [email protected]

Johan v Rensburg Illovo - Noodsberg Engineering Manager (033) 5011650 [email protected] Barry Holmes Illovo - Eston Factory Manager (031) 7811092 [email protected] John Hulley Illovo - Pongola Factory Manager (03441) 31301 [email protected] Vis Pillay Illovo – Sezela Factory Manager (039) 9751106 VisPillay@illovo

Morne Bester Illovo – Umfolozi Plant Engineer (0355) 500031 082 923 6322 [email protected] Lal Bachan Illovo – Umzimkulu Factory Manager (0396) 824202 083 627 4188 [email protected] Allan Ferguson Tongaat-Hulett Group Engineer (032) 4394328 [email protected]

Dave Meadows Tongaat-Hulett Manager TEG (032) 4394311 [email protected]

Deon v/d Berg Tongaat-Hulett Regional Operational Manager (0357) 915000 082 808 5163 [email protected]

Nigel Simmonds Tongaat-Hulett – Darnall Engineering Manager (0324) 392231 082 806 7975 [email protected]

Jonathan de Jager Tongaat-Hulett – Felixton Engineering Manager (035) 7915000 [email protected] Stuart Watson Tongaat-Hulett – Maidstone Engineering Manager (032) 4395502 082 3780817 [email protected] Franco Weyers Transvaal Suiker BPK - Malelane Factory Manager (013) 7911000 082 8794748 [email protected]

Graham Rolfe Transvaal Suiker BPK - Komati General Manager (013) 7234860 [email protected]

Peter von Fintel Union Co-op Sugar Mill Mill Manager (033) 5011600 082 4932775 [email protected]

Karl Schroder Union Co-op Sugar Mill Engineering Manager (033) 5011600 [email protected]

Eckard Lucht UShukela Milling Factory Manager (0325) 513031) [email protected]


Government Name Organisation Position Phone Cell E-mail

Kevin Nassiep Department of minerals & energy Chief Director (012) 317 8617 [email protected]

Brett Dawson Department of minerals & energy Director Renewable Energy (012) 317 8468 [email protected]

Andre Otto Department of minerals & energy Deputy Director Renewable Energy (012) 317 8225 [email protected]

Marcus Phago Department of minerals & energy (012) 317 8568 [email protected]

Nadia Hamid Department of minerals & energy (012) 317 8657 [email protected]

Sandiswa Tshaka Department of minerals & energy (012) 317 8569 [email protected]

Olga Lindiwe Department of minerals & energy (012) 317 8565 [email protected]

Nomawabo Mtshabe Department of minerals & energy (012) 317 8347 Nomawabo. [email protected]

Helene Rask Gron COWI International Project Manager (012) 317 8532 [email protected]

Kumesh Naidoo COWI Local Renewable Energy Advisor (012) 317 8597 082 5631363 [email protected]

Sibusiso Ngubane Central Energy Fund (CEF/EDC) Renewable Energy Manager (011) 535 7039 082 413 0475 [email protected]

Sizwe Madondo Central Energy Fund (CEF/EDC) Manager Business Services (011) 535 7041 082 3749777 [email protected]

Jabulani Shabalala Central Energy Fund (CEF/EDC) Project Officer (011) 535 7048 082 5660522 [email protected]

N Singh National Energy Regulator (NER) (012) 401 4617

Smolly Lebepe National Energy Regulator (NER) (012) 401 4600 [email protected] Jeffrey Quvane National Energy Regulator (NER) (012) 401 4600 [email protected] Johan Crous ESKOM (011) 800 4457 [email protected] Ronel Clark ESKOM TSI (011) 629 5062 Shanita Makardood ESKOM TSI (011) 629 5122

ESKOM Izak van Gass ESKOM TSI (011) 629 5413 Johan Bester DWAF (012) 336 8171 082 808 5634 [email protected] Sam Falatsa DWAF working for water (021) 441 2725 [email protected]

Callie Nkomo


Others Name Organisation Position Phone Cell E-mail

D Dintchev University of Pretoria Professor (012) 799 9512 082 847 5039 dintchev@icon .co.za

Dave Hancock GTZ (011) 535 7027

Anton Louis Olivier NU Planet (012) 349 1901 [email protected] Sadvir Bissoon SA Bureau of Standards (012) 428 6761 [email protected]

Palma Development Consultants (012) 349 1901 [email protected]

Edward James Smith Roskilde University Denmark (011) 728 8002 [email protected]

Rob Short Sustainable Transactions 082 454 2193 [email protected] Jason Schaffler Nano Energy Managing Director 072 444 3445 [email protected] David Chown Genesis Eco Energy (021) 783 5814 083 460 3898 [email protected] Wallie Menne Timber Watch 082 444 2083 [email protected] Charles Liebenberg MethCap (pty) ltd (011) 660 5035 072 954 7116 [email protected] Richard Worthington Earthlife Africa 082 446 6392 [email protected]

GreenNetwork (033) 345 2045 [email protected]

Mike Page SAD-ELEC (011) 803 1314 082 416 2875 [email protected]

Ruth Modipa Gendes RE Program

Victor Taylor 082 493 8343 [email protected]

Erica Roberts

Sandile Ndawonde


S:\Onassis\Final Report Biomass.doc .

Documents

Final Report Biomass