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DKTI - Development of a Sustainable Bioenergy
Market in Serbia
German Climate Technology Initiative (DKTI)
Technical assistance module by GIZ
Working Areas DKTI for Project Devlopment
In the private sector, we support the implementation of innovative self-sufficient
bioenergy projects using wood material, organic waste and agro-biomass to substitute
fossil fuels for heat, steam and electricity generation integrating private and public
stakeholders for long-term international technology partnerships.
Therefore three main different working areas has been chosen:
Biogas production for company own process heat consumption or CHP electricity
generation with organic waste or organic waste water (manure, whey etc.) in
cooperation with agro-industry
Straw-combustion projects for process heat /steam generation
Heat generation of wood material (Pellets, Briquettes, Woodchips) for public and
private buildings (Hotels, Schools, Hospitals or Investors/Contractors)
Chart 2
Main Activities DKTI for Project Devlopment
Identification of projects and potential investors for bioenergy heating systems in public
buildings, biogas facilities, facilities for generation of industrial process heat
Consultancy for plant design and project concepts
Elaboration of bankable (pre-) feasibility studies
Support/Intermediation of financial opportunities and investment subsidies
Business Match-Making and election of national and international technology providers
Logistical concepts for agro-biomass
Technical support for permit application and support to increase the efficiency of processes
related to permits and licensing agreements for bioenergy projects
Best-Practice-Documentation, Support of research work in cooperation with Universities,
Capacity-Building
Dialogue-platform for Serbian and International companies and institutional stakeholders to
exchange project ideas, information and experiences
Publishing of success stories, manuals etc.
Chart 3
PRE-FEASIBILITY STUDY
Fuel switch from gas to a straw-fired steam boiler plant
for company Perutnina Ptuj-Topiko
at poultry processing facilities in Backa Topola
Study project assigned by:
Development of a Sustainable Bioenergy Market in Serbia
Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ) GmbH
Bože Jankovića 39
11000 Belgrade, Serbia
www.giz.de
Responsible project manager: Thomas Mitschke, Senior Advisor
Study prepared by:
Hermann Wieser
Management & Renewable Energy Consultant
Annastrasse 19
9210 Pörtschach am Wörthersee, Austria
www.wieserconsult.com
Chart 5
Overview of presentation
■ Basic concept
■ Biomass potential of Municipality Bačka Topola
■ General characteristics of straw as renewable fuel
■ Existing gas-fired steam boiler plant at PPT processing factory
■ Proposed plant types and capacity of biomass-boiler
■ Biomass storage (field-storage and on-site storage)
■ Ash handling
■ Primary energy cost of different energy carriers in Serbia
■ Agro-biomass market in Serbia and Backa Topola
■ Economic strategy and evaluation of profitability
(ROI, Pay-back-time, IRR, Sensitivity analysis)
■ Investment structure
■ Time schedule for realisation and next steps
Chart 6
Basic concept
STRAW-FIRED
STEAM BOILER
PLANT
1,7 MWth
Wheat straw
1.563 tons/year
Chart 7
Soya straw
~5.440 MWh
steam
TOTAL STEAM
PRODUCTION
~5.440 MWh/year
Corn straw
Economic and agribusiness snapshot of Backa Topola Municipality
Chart 8
Info Data
Total area 596km2
Number of
settlements23
Total population 33,321
Urban population 18,748
Rural population 14,573
Settlements
Backa Topola, Bagremovo, Backi Sokolac, Bajsa, Bogaras, Gornja Rogatica, Gunaros,
Karadjordjevo, Kavilo, Krivaja, Mali Beograd, Micunovi, Njegosevo, Novo Orahovo, Obornjaca,
Pacir, Panonija, Pobeda, Srednji Salas, Stara Moravica, Sveticevo, Tomislavci, Zobnatica
Agricultural land structure of Backa Topola Municipality
Chart 9
InfoTotal land
area
Agricultural land
Arable land Forest land other land
Utilized Unutilized
Area (ha) 57,050 49,378 1,000 48,868 599 6,073
Share (%) 100% 87% 2% 86% 1% 11%
307 6722.483
3.2964.295
3.0744.438
7.952
22.861
0
5.000
10.000
15.000
20.000
25.000
Bellow1ha
1-2ha 2-5ha 5-10ha 10-20ha 20-30ha 30-50ha 50-10ha over100ha
Agro-biomass potential of Backa Topola Municipality
Chart 10
Average Production (t)
2009-2013
Grain - Straw
proportionTotal straw yield (t)
Agro biomass
potential (t)
(30% of straw yield)
Wheat 51,454 1:1 51,454 15,436
Corn 153,610 1:1 153,610 46,083
Soya 4,563 1:2 9,126 2,738
Total 214,190 64,257
Characteristics of straw bales
Rectangular straw bale
Dimension: 1,2 x 1,2 x 2,5 m
Weight: ~ 400 kg (high density up to 750 kg)
Energy quantity: ~ 1,56 MWh
Heating value: ~ 3,9 kWh/kg
Equivalent: ~150 l heating oil or ~160 m3 gas
One truck with average 20 tons equivalent
to 8.000 litres heating oil or ~8.100 m3 gas
Chart 11
Characteristics of wheat straw
Average grain yield: 6,5 tons/ha
Average straw yield: 5,2 tons/ha
Grain straw proportion: 1 : 0,8
Straw yield Vojvodina: ~ 2,5 tons/ha
Heating value: ~ 3,9 kWh/kg
Mostly baled field crop in Europe
Advanced harvesting technology and experience
available
Experience for energetic use due to clear biomass
directives in Denmark, Great Britain and Spain
Energetic use in Germany, Austria, Southeast
Europe and in particular in Serbia at beginning
Chart 12
Characteristics of corn straw
Average grain yield: 6,8 tons/ha
Average straw yield: 8,9 tons/ha
Grain straw proportion: 1 : 1,3
Straw yield Vojvodina: ~ 5,5 tons/ha
Heating value: ~ 4,1 kWh/kg
Second mostly used field crop in Europe; commonly
used in Southeast Europe and particular in Vojvodina
Advanced harvesting technology and experience
available – similar technology as for wheat straw
Higher water content of corn straw at harvest but this
depends on local conditions
Used for production of agro-pellets
Chart 13
Characteristics of soya straw
Average grain yield: 3,5 tons/ha
Average straw yield: 2,3 tons/ha
Grain straw proportion: 1 : 0,6
Straw yield Vojvodina: ~ 2 tons/ha
Heating value: ~ 3,8 kWh/kg
Increasing demand for growing of soya in Danube
Region area
Baling similar to wheat straw with bale presses
Experience of soya straw baling in Vojvodina
Slightly lower heating value than wheat and
corn straw
Chart 14
Existing gas-fired steam boiler plant at PPT processing factory
Chart 15
Capacity of gas boiler in main use 3.000 kW
2 gas boilers in use of which one will remain as
back-up/one will be removed
Yearly gas consumption around 500.000 m3
Steam is maintained by on/off control of gas burner
Starts around 6 bar – raises pressure
Required pressure: 6-8 bar
Common steam header with existing boiler
Heating of technological water consumption (meat processing)
06:00 – 14:00 hour high consumption. 2 shifts, 5 days/week operation
Cleaning in between weekends
Estimated load curve of existing gas boiler
Chart 16
Figure: Estimated daily load curve based on provided data by Perutnina Ptuj-Topiko
Estimated load curve as basis for new straw-biomass boiler
Chart 17
Figure: Estimated daily load curve as basis for design of new straw-fired biomass boiler
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
12
05
409
613
817
102
11
22
51
42
91
63
31
83
72
04
12
24
52
44
92
65
32
85
73
06
13
26
53
46
93
67
33
87
74
08
14
28
54
48
94
69
34
89
75
10
15
30
55
50
95
71
35
91
76
12
16
32
56
52
96
73
36
93
77
14
17
34
57
54
97
75
37
95
78
16
18
36
58
56
9
Load curve (hourly) in MW
Biomass Gas
Demand Biomass Gas
%5.246
97% 3%
MWh 5.067 179
Plant type A: WEISS A/S boiler (flow chart)
Chart 18
Figure: Exemplary flow chart of a 3 tons/hour steam boiler plant fired with straw bales provided by company WEISS A
Plant type B: LIN-KA Maskinfabrik A/S
Chart 19
Figure: Cross-section drawing of straw storage and
attached boiler house provided by LIN-KA
Maximum continuous output 1.700 kW
Maximum steam output 2.500 kg/h
Working pressure: 8 bar
Minimum feed water temperature 105°C
Max. fuel volume 450 kg/hour
On-site biomass storage
Storage capacity for one week maximum boiler load capacity during winter
time recommended
Max. fuel demand: 0,4 tons/hour and 68 tons per week
Required storage capacity for 170 bales (avg. bale weight 400 kg)
Chart 20
Bale type Heston
Weight/bale: 400-500 kg
Width 1.200mm
Height 900mm
Length 2.500mm
Heating value ~1.560 KWh
Loading band 21,4 m (8 bales)
Fuel demand 14 – 20 bales/day
Loading times 2 – 3 times/day
Plant type B: LIN-KA Maskinfabrik A/S
Chart 21
Figure: Typical layout plan for straw steam boiler plant provided by LIN-KA Maskinfabrik A/S
Location of biomass plant at production facilities at Backa Topola
Chart 22
Figure: Positioning of boiler house, closed straw storage, open straw storage and optional roads for straw
delivery and removal of ash
Straw storage organisation
Chart 23
Figure: Straw storage organisation according to Serbian Rule Book on Special Fire Provention
Mesures in Agriculture
Bale dimensions w=1.2m, l=2.4m, h=1m
Bale weight = 400kg
Required amount of straw = 1,300t
Number of bales = 3,250
Stacking height = 6 meters
Bales in one pile = 240
Number of piles = 14
Total area required for storage = 32 x 260 m or 0.832 ha
Ash handling
■ The ash from the combustion of uncontaminated agricultural residues
is a valuable fertiliser and can be distributed back to the fields
■ 4% - 10% average ash part from straw remaining after combustion
■ 1.560 tons of straw = 62 - 156 tons of ash/year
Nutrient matter Bottom ash Cyclone ash Micro fly ash
in % of dry matter
Calcium (CaO) 7,8 5,9 1,2
Magnesium (MgO) 4,3 3,4 0,7
Potassium (K2O) 14,3 11,6 48,0
Phosphor (P2O5) 2,2 1,9 1,1
Sodium (Na2O) 0,4 0,3 0,5
Nutrient content of different ash types from straw combustion; Source: Kaltschmitt, Hartmann,
Hofbauer; Springer Verlag 2009
Chart 24
Primary energy cost of different energy carriers in Serbia
Source: Different energy carriers in Serbia and their calorific value and price (not including transport cost);
Desk research of different studies and expert talks Chart 25
Energy carrier UnitCalorific value
in kwh per unit
Price per unit Price per kWh
EUR in Euro Cent
Straw in bales ton 3,900 40.00 1.03
Electricity kWh 1 0.06 5.50
Natural gas m3 10 0.37 3.70
LPG litre 10 0.91 9.06
Diesel litre 9.8 1.16 11.83
Fuel oil (Mazut) kg 11.8 0.35 2.97
Wood chips
(wc = 30%)ton 3,500 55.00 1.57
Pellets, briquettes ton 4,800 150.00 3.13
Coal Vreoci mine ton 5,210 75.00 1.44
Agro-biomass market situation in Backa Topola Municipality
Table: Straw suppliers in Vojvodina
Chart 26
Straw supplier Location
Betacorn doo Sombor
Mediland doo Sombor
Vasa Poljanski Vrsac
Sreckov Dragan Novi Sad
Bun Petar Ada
Most important straw buyers in Backa region are:
Compost producers
Chicken and cattle farms
Agro pellet and briquette factories
Companies producing energy from straw
Straw prices in Serbia in 2015
Chart 27
Product-parity Price
Straw on field EUR/ha 12-24
Straw on field EUR/ton 6-8
Straw loaded on truck EUR/ton 25-29
Straw transported to sellers’ storage up to 50km EUR/ton 38-42
Straw transported to sellers’ storage over 100km EUR/ton 50
Economic strategy
■ Reduction of energy cost of actual 41,00 €/MWh or 28,00 €/t steam
■ Change from fossil to Renewable Energy
■ Greening of company and products
Heat / steam production 5.400 MWh
Gas price 37 €/MWh 222.000
Electricity 1,0% 60 €/MWh 3.240
Staff 10.000 € 10.000
Maintenance 11.000
Depreciation 0
Interest 0
Total 41,00 €/MWh 246.240
28,00 €/t steam
Source: Own calculation of present heat production cost
Chart 28
Evaluation of economic profitability
Chart 29
4 Options are calculated in the feasibility study
Plant type A
Option 1: WEISS A/S technology, automatic crane system, no grant
Option 2: WEISS A/S technology, manual straw handling, IPARD grant
Plant type B
Option 3: LINKA technology, manual straw handling, no grant
Option 4: LINKA technology, manual straw handling, IPARD grant
IPARD Program 2014-2020
Chart 30
Within the IPARD sub-measure “Investment in physical assets concerning
processing and marketing of agricultural and fishery products” the sector of
meat processing (poultry production of Perutnina Ptuj-Topiko) may be eligible for
submitting a project proposal to support the investment in renewable energy
production used for own consumption of the processing factory.
Aid intensity
Aid intensity, expressed as the share of public support in the eligible expenditure of an
investment amounts up to:
50% of total eligible expenditures
Maximum eligible investment expenditure is EUR 1.000.000
Investment cost – Option 4
Source: Data provided by LINKA A/S and own calculations
Chart 31
Investment cost EUR
Project development / permitting 50.000
Buildings (756 m2 x 258 €/m2) 196.000
Machinery and equipment including
straw handling590.000
Miscellaneous 60.000
Total estimated investment cost 896.000
IPARD grant (50% of investment) -448.000
Investment cost after IPARD grant 448.000
Source: Own calculations according to profitability analysis
Chart 32
Evaluation of economic profitability Euro
Investment 896.000
Equity 40% 358.400
Grant 50% 448.000
Loan 10% 89.600
Interest rate / period 6% 10 years
Persons employed / cost per year in € 1 15.000
Installed plant capacity (heat) MWth 1,7
Operation time hours/year 3.200
Heat output per year MWh 5.440
Heat price EUR/MWh 41,00
Input materials (straw bales) tons 1.563
Cost of straw bales EUR/ton 40,00
Evaluation of economic profitability
*) Cost including expenses for fuel, production, operation, no depreciation and interest due to existing plant
**) Cost including expenses for fuel, production, operation, depreciation and interest
■ The project shows a reasonable profitability
ROI – Return on Investment in % 10,4
Payback time in years 9,7
■ Comparison of production cost in MWh and per ton of steam
Existing
gas boilers
New agro-biomass
steam boiler plantDifference
Cost per MWh in € 41,00* 31,50** -9,50
Cost per ton of steam in € 28,00* 21,50** -6,50
Source: Own calculations according to profitability analysis
Chart 33
Evaluation of economic profitability
IRR – Internal rate of return
Source: Own calculations according to profitability analysis
Chart 34
-600.000
-500.000
-400.000
-300.000
-200.000
-100.000
0
100.000
200.000
300.000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Incomes Costs Balance
NPV NPV - Costs increase 10% NPV - Income decrease 10%EUR
34,40%26,50%25,75%
171%155% 154%
0,00%
50,00%
100,00%
150,00%
200,00%
Evaluation of economic profitability
Sensitivity analysis
Source: Own calculations according to profitability analysis
Chart 35
0%
10%
20%
30%
40%
50%
60%
70%
80%
70% 80% 90% 100% 110% 120% 130%
IRR
in
tern
al
rate
of
retu
rn
Change in comparison to the initial valueINVESTMENT COSTS Gas price Straw price
Environmental contribution - CO2 savings
Chart 36
Energy carrier Calorific value CO2 output CO2 savings
1 m3 gas 10 kWh/m3 2 kg/ m3 -
1 ton straw 3.900 kWh/ton - 0,76 kg/ton
1.563 tons straw 3.900 kWh/ton - 1.188 tons*
The calculation is based on the assumption of 0,76 tons CO2-reduction by using one ton of straw (calorific value 3,9
kWh/kg, water content 15%) instead of 1 m3 natural gas (calorific value 10 kWh/m3 and CO2 output of 2 kg/m3)
muliplied with 1.563 tons of straw (1.563 * 0,76 = 1.188). The calculation doen´t include CO2 emissions related to
the harvesting and transport of straw.
Investment structure
Chart 37
Financial sources – Structure of
investmentType of contribution
Investor: Perutnina Ptuj-Topiko Equity, land for construction of biomass plant
Energy fund Equity and/or loan financing/eventually grants
Commercial banks Loan financing
EU IPARD Program Grant
EBRD WeBSEFF Grant, loan
National/regional Government Grants, investment incentives, tax exemptions
OthersNeeds to be determined during financing
negotiations
Time schedule for realisation and next steps
■ Realisation time: 8 – 16 month after assignment
Basic decision for project realisation by management board of company Perutnina
Clarification of financing in terms of equity, bank loans and applying for project funding
Obtaining offer from straw boiler producers and decision for boiler technology and
ordering of machinery and equipment
Project development
Assignment of architect for designing of buildings and achieving of construction
permit based on decision for boiler technology
Assignment of environmental engineering company for applying of environmental
permit based on decision for boiler technology
Chart 38
Contact: – Marijana Nikolic, Project manager-Component Project Development
E-Mail: [email protected]
Deutsche Gesellschaft für
Internationale Zusammenarbeit
(GIZ) GmbH
Development of a Sustainable
Bioenergy Market in Serbia
Bože Jankovića 39
11000 Belgrade
Serbia
T +381 11 3912 507
Thank you for your attention
Chart 39
