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WÄRTSILÄ Biopower plants
WÄRTSILÄ PRESENTATION
1st of June , 2006
Jussi Mikkola JMC Services
For Wärtsilä Biopower Oy
Biopower
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Biopower Strategy
Concentrate on small (< 10 MWe) plants
Main strategic steps: – Buy a suitable entry business with
the assets we need – Concentrate on ”green markets” to
generate delivery volume – Through modularization and serial
production reduce the costs of small bio power plants radically
– Buy technology & know-how, expand to agro fuels & tropical markets
BioGrate Boilers, Wood Fuels
New products & competencies
CHP Plants
Tropical Markets
”Tropical Acquisition”
”Sugar Bagasse, Rice Husk”
”Starting Position”
New Fuels
“Green” Electricity Markets
Improve Performance
Home Markets
Major Challenges
0
20
40
60
80
100
120
140
Fuel source size
No. of sources
Power plant size 0
20
40
60
80
100
120
140
Wärtsilä Biopower
$/MWe
Amount of available fuel sources versus size
“Economies of Scale”- plant investment costs versus size
The cost of the delivery chain does not follow the plant size
– Design, equipment, installation, automation, electrification, documentation
Standardization – minimizing the design work
– standard equipment
– minimized installation time and manpower
– modular product delivery
Target: 50 – 70% standardization
Challenge: Economies of Scale
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BioPower Product Portfolio
BioPower 5 (Steam 50 bar(a), 480°C) 17 MWth boiler Plant type MWe Thermal Note BioPower 5 DH 3.7 13.0 MW 90/50°C DH water BioPower 5 HW 3.1 13.5 MW 115/90°C Hot Water BioPower 5 ST 2.4 20.5 t/h 4 bar(a) / 95°C Condensate BioPower 5 CEX 4.0 – 5.3 Up to 17 t/h steam 2 bar(a) BioPower 5 C 5.4 - Power only (C.W. 25/35°C) BioPower 7 (Steam 62 bar(a), 480°C) 23 MWth boiler Plant type MWe Thermal Note BioPower 7 DH 5.1 7.7 MW 90/50°C DH water BioPower 7 CEX 5.3 – 7,3 Up to 24 t/h steam 2 bar(a) BioPower 7 C 7.4 - Power only (C.W. 25/35°C)
Standardization Rotating BioGrate© combustion for wet fuels
Water tube boiler (natural circulation)
Impulse turbine + generator
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Patented, rotating conical grate
Combustion area divided into several ring type, rotating zones
Zone controlled primary air inlet for efficient combustion
Three stage combustion air inlet for low NOx emissions
Fuel feeding from the centre bottom
Under grate wet ash removal
Designed for wet fuels up to 65%-w
Long lifetime Reliable operation High efficiency combustion Low NOx and CO
BioGrateTM - Combustion Technology
BioPower 5 Steam Boiler
ECONOMISERS
CONVECTIVE. EVAPORATOR
PRIMARY SUPERHEATER
SECONDARY SUPERHEATER
MEMBRANE WALL DRUM BOILER WITH NATURAL CIRCULATION
STEAM OUTPUT 17 MW
FEED WATER TEMPERATURE 105 °C
FEED WATER PRESSURE 62 BAR(a)
OPERATION PRESSURE 50 BAR(a)
OPERATION TEMPERATURE 480 °C
STEAM FLOW 21 T/h
5.83 kg/s
EXHAUST GAS TEMPERATURE 150 °C
MEMBRANWALL COMBUSTION CHAMBER
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BENEFITS TO THE CLIENT
FAST QUOTATION
CONSISTENT QUALITY
TESTED COMPONENTS
CLEAR SCOPE OF SUPPLY
FAST SCHEDULES
ECONOMICALLY ATTRACTIVE PRICE LEVEL
SERIAL PRODUCTION BENEFITS
STANDARDIZED SOLUTIONS – PRE DESIGN
– VARIATIONS WITH OPTIONS
MODULAR PRODUCT STRUCTURE – PREFABRICATED MODULES AND UNITS
TRANSFER OF ASS’Y WORK FROM SITE TO FACTORY
EFFECTIVE SITE WORK
NET WORKING WITH GLOBAL PARTNERS
Construction
Benefits of the Cogeneration
Total Efficiency
62 % Existing production system
Total Efficiency
85 %
136 MWh Fuel
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81
Power plant 40 % efficiency
Heat boiler 80 % efficiency
100 MWh Fuel
Bio Power plant
20 % el efficiency 65 % heat efficiency
Bio cogeneration
20 MWh Power
65 MWh Heat
Transmission lost
10 %
20 MWh Power
65 MWh Heat
Global energy savings >25 %
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Bioenergy has become a favored alternative
CO2 emission-neutral energy Own heat load is important and
valuable source for CHP Enables CHP with high
efficiency and low environmental impact
CHP plant provides high total economy
Wärtsilä BioPower is reliable, efficient and environment-friendly solution
Summary
www.wartsila.com
Grainger Sawmills, Ireland
One of the leading sawmills in Ireland
Bark, saw dust, wood chips
BioPower 2 CEX 3,5 MWth / 1,9 MWe
> 80 % of electrical power and 100% of thermal energy need of the sawmill
Turn-key delivery
Start of commercial operation April 2004
BioPower Reference
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Reference - Finnforest Vilppula
BioPower 5 HW + BioEnergy 9
Contract 4/2003
Start commercial operation 2/2004
Heat for drying kilns and Vilppula city
Electricity generation 23 GWh
Heat production 132 GWh (105 GWh by CHP)
Fuel consumption 190 GWh Sawmill residuals Bark, sawdust, wood chips
BioPower Reference
Customer is Finnforest Oyj – one of the biggest sawmill companies in Europe
Sawmill’s capacity > 240 000 m3/a,
Bark, saw dust, wood chips
BioPower 2 HW 8,0 MWth / 1,3 MWe
Contract 4/2003
Handing over 2/2004
Renko Sawmill, Finland
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Marks Värme Ltd, Sweden
Municipal District Heating
Bark, saw dust, wood chips
BioPower 5 DH, 16.5 MWth / 3,5 MWe
Contract 2/2004, Handing over early 2005
BioPower References
BioPower References Trollhättän energi, Sweden
Municipal District Heating
Bark, saw dust, wood chips
BioPower 5 DH, 16.5 MWth / 3,5 MWe
Contract 2/2004, Handing mid 2005
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BioPower References Trollhättän energi, Sweden
Municipal District Heating
Forest Residue Chips
BioPower 5 CEX, 5,3 MWe / 3,5MWth
Contract 11/2004, Handing 4/ 2006
Thank You!
www.wartsila.com
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Concrete foundations and floor
How to build a biomass plant
Foundation and earth moving works done - 10.5.2006 = Day 0 - 6…8 weeks working time before day 0 = foundations ready for loading
- Excavation - Sewages and cable excavation - Fillings - Earthing grid - Molding boxes - Installation of sewages - Concreting - Installations of base bolts - Measurements
Boiler lower part
Start of mechanical installations - Main lifting 2 - 2 weeks working time
- Welding and assembly combustion chamber
Combustion chamber pre welding before lifting 10.5 – 18.5.2006
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Boiler upper part
Economizer
Steam Drum
Boiler lifting done – Main lifting 2 - 2 weeks from day 0 = 24.5.2006 - ½ weeks working time
- Lifting of boiler, eco - Lifting of oil boiler and stack at the same time
Boiler pre welding before lifting 10.5 – 23.5.2006
Stair Tower
Stair tower installations starts - 2 weeks from day 0 - 2 weeks working time
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Venting Module Live Steam Module Feed Water Tank Module
Blow Down Tank Module
Make-up Water Tank
Module lifting starts - 2 weeks from day 0 - 1½ weeks working time
- Modules at foundation level - Fuel feeding bin and conveyor inside of the boiler house - Ash conveyors
All the modules and stair tower installed - 6 weeks from day 0 = 23.6.2006 - Primary supporting steels and platforms assembly done - Assembly of pipes and ducts starts - Installation of boiler down comers and risers starts - Building frame installation is ongoing at the same time
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Steel for building
Building frame and platforms ready - 7 weeks from day 0 = 30.6.2006 - Building frame installation done and continue with wall installations - Mechanical installations continues
Walls
Wall installations done - 10 weeks from day 0 = 19.7.2006
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Roof
Roofs closed - 12 weeks from day 0 = 1.8.2006 - Electrical installations starts
Radiators Electrical filter Process equipment and connections work starts - 15 weeks from date 0 = 15.8.2006 - Radiators - ESP - Pipeline bridges
Back
03/10/11
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PLACE PICTURE OF YOUR CHOICE HERE.
For approved photos visit http://w3/communications/brand_central/ (Brand Central Station) and take a look at the Image Library.
2nd International Bio-energy Conference & Exhibition
Ken McDonald Executive Assistant to the Senior Vice-President Distribution May 31, 2006
Distribution Line of Business
Outline
• Biomass as an electricity generating resource
• Opportunities in BC
• Challenges to electricity production
• Alignment with BC Hydro’s future plans
03/10/11
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Distribution Line of Business May 31, 2006
Why Biomass for electricity production?
• It is a carbon neutral energy source depending on prescribed levels of emissions
• Derived from industrial by-product
• Potentially a significant source of process heat and electricity in the forestry and pulp and paper industries, ie self-generation
• Renewable and sustainable when managed in accordance with contemporary standards
• Biomass electricity projects can be EcoLogo certified
Distribution Line of Business May 31, 2006
Common Sources
• Agricultural residue • Pulp and paper mill residue • Urban wood waste • Municipal solid waste • Forest residue • Energy crops • Landfill methane • Animal waste
03/10/11
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Distribution Line of Business May 31, 2006
Challenges to Biomass Electricity Generation
• Costs may be prohibitive due to large boilers and waste-handling plant needed
• Fuel handling and storage cost is much higher than for gas fired or coal fired plants
• Heat rates of 14,000 to 18,000 BTU per kWh yield efficiency rates of only 18% to 24%
• Most competitive projects are located in areas of low priced feedstock and/or where electricity selling prices are high
• Long-haul transportation costs are high
• Slow response to customers’ peak demand
• Suppliers of biomass have other growing and higher value markets for their resource
• Long term fuel supply and financing a challenge for some projects
Distribution Line of Business May 31, 2006
Benefits of Biomass Electricity Generation
• Reliable supply with both dependable capacity and firm energy
• Recycle wood waste and other residues
• Potential benefits vary with availability of fuel source
• Emission mitigation costs borne by developer ?
• Identified within BC Clean Guidelines (Provincial Energy Plan 2002)
• May be certified as Green Energy under EcoLogo
03/10/11
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Distribution Line of Business May 31, 2006
Current Status of Biomass Generation in BC
Existing Generation Competitive Acquisition Activities • F2006 Open Call (underway)
• Planned calls in F2007 and F208 as outlined in the 2006
Integrated Electricity Plan
Distribution Line of Business May 31, 2006
BC Hydro’s F2006 Open Call for Power
• 37 bidders
• 53 separate projects representing 1,800 MW of new electricity generation
• Target for call is 2,500 GWh per year and firm energy tendered totals approx. 6,500 GWh per year
• Scale ranges from large, firm energy projects to smaller projects with no firm delivery commitment
• Project types are biomass, hydro, coal, waste heat, and wind
03/10/11
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Distribution Line of Business May 31, 2006
BC Hydro’s 2006 Integrated Electricity Plan
• 20 year electricity plan to meet future supply gap
• Plan addresses:
> What will we need?
> What options are there to meet the need?
> When will we need it by?
• Plan has been filed with 10-year Action Plan called the Long Term Acquisition Plan (LTAP) to the BC Utilities Commission for public review
Distribution Line of Business
03/10/11
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Distribution Line of Business
BC Hydro Overall Supply Mix
Acquisition Results Online Now
13% (7,100 GWh)
87% (47,000 GWh)
Acquisition Results Currently Contracted
19% (9,000 GWh)
81% (47,000 GWh)
IPP BC Hydro
Distribution Line of Business
BC Hydro IPP Supply Mix
Contracted IPP Energy by Size
12%
74%
14%
0-1MW 1-50 MW >50 MW
1% 10%
31%
58%
Biogas Biomass/Woodwaste Gas Hydro
Contracted IPP Energy by Technology
03/10/11
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Distribution Line of Business
Potential Energy Contribution by Resource Type
0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Small Hydro
Large Hydro Demand Side Management
Natural Gas - Resource Smart
Natural Gas
Coal
Wind
Geothermal
Biomass
Wave
Tidal
Solar
Average Annual Energy (GWh)
Resource Options Additional Resources Available Future Resource Options
Distribution Line of Business
Unit Energy Cost Range for Each Resource Type
020406080
100120140160180200
Small HydroLarge Hydro
Demand Side ManagementNatural Gas - Resource Smart
Natural GasCoal Wind
GeothermalWave Tidal
UnitEnergyCost($/MWh)
Min. Weighted Ave. Max.
Solar:Max. = $1565/MWhWeighted Ave. = $1330/MWhMin. = $697/MWh
Small H
ydro
Larg
e Hyd
ro
Deman
d Side
Mgm
t
Natura
l Gas
- Res
ource
Smar
tNatu
ral G
as
Coal
Wind
Geothe
rmal
Biomas
s
Wav
e
Tidal
Uni
t Ene
rgy
Cos
t ($/
MW
h)
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03/10/11
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Distribution Line of Business May 31, 2006
Resource Options
• Conservation Initiatives
• Reinvesting in Heritage Assets
• Acquiring from Independent Power Producers
> Large and Small hydro
> Wind
> Geothermal
> Customer Cogeneration
> Biomass
> Coal
Distribution Line of Business May 31, 2006
Reinvesting in Heritage Assets
• Revelstoke 5 > 500 MW of additional capacity to existing generating
facility
> Provides new opportunities for clean and green intermittent resources such as wind and run-of river
• Burrard Thermal
> Staged and flexible approach to replace both capacity and energy prior to planned phase out
03/10/11
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Distribution Line of Business May 31, 2006
Potential Large Scale Projects Beyond 10 year horizon, need to start dialogue on options for large scale development. Some examples that could be considered include: • Site C
> Decision of Provincial Government > 900 MW ≥ 8% of existing needs > 4600 GWh per year ≥ 460,000 homes > Requires assessment of costs, environmental considerations and community
and First Nations concerns
• Large Scale Coal Fired Facility
> Currently can bid in Open Call process > Abundant resource at stable, low cost > Dependable firm power > Operating & maintenance costs greater than large hydro > Shorter life span than large hydro > Environmental costs need to be considered over facility life span > Likely to be private sector
Distribution Line of Business May 31, 2006
In Closing
• Biomass continues to provide an opportunity for electricity generation by the private sector in the province
• Industry needs to be assess opportunities against other higher value uses and provincial strategy, ie Energy Plan update and Mountain Pine Beetle strategies
• Opportunity identified in BC Hydro’s long term electricity plan and is valued as a viable firm resource option
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Community-Based Mill Waste Utilization May Hold New Promise for Production of Steam and Electricity
on the Western Olympic Peninsula Larry Mason - University of Washington
June 1, 2006
Struggling Forest Industry
Increasing Government Regulation
Lost Jobs
Declining Rural Economies
A Compelling but not Uncommon Story in Recent Years for the Pacific NW…
… this time, however, what starts as disaster may become opportunity.
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Forks, Washington
Olympic Peninsula
Project Background • July 2005 - Shingle Mill Burners to be shut down
by air quality regulations.
• March 2005 – Economic Development Council asks for help.
• April 2005 – University Investigation:
• Characterize cedar industry
• Quantify the problem
• Analyze waste test results
• Identify utilization/disposal options
• Describe costs
• Determine most promising alternative
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Characterize the Industry: Once a major source of economic activity…
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with high production manufacturing capacity.
As little as 20 years ago, more than 100 shingle mills operated in western Clallam County. Today only 11 small mills remain.
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Not as big as it used to be but still an important contributor to a struggling rural forest-based economy.
11 Mills • 17 Shingle saws/ 6 Shake saws
• 100,000 + square/ year
• 13,000 + cords (~ 16 – 17 MMBF equivalent)
• 55+ direct jobs with ~130 cutters, truckers, helicopter people, pallet makers, accountants, etc.
• 500+ indirect jobs
• Gross sales >$10 million
• State Taxes >$2.5 mil/ Federal Taxes >$4.5 mil
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Changes in Air Quality Regulations Mean No More Waste Burners
Composition of Cedar Mill Residuals, 1988 - 2000
0%
20%
40%
60%
80%
100%
1988 1992 1996 2000 est.
% o
f Tot
al W
aste
sawdust/tow slivers/pieces bark
Today shingle blocks, not logs, are brought from the woods.
Waste is less, and not as coarse, but, without burners, disposal is problematic.
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Shingle tow, slivers, and pieces do not meet the size and consistency requirements of paper mill boiler conveyers (3” minus).
The Problem:
Mills have no local grinding capabilities. Paper mill is only available disposal. Shingle waste must travel 60 mi. Mill must pay trucking and
grinding costs.
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Tub Grinder accepts delivered material for $2/GT fee.
Before After
Western red cedar Douglas-fir Western hemlock Big leaf maple Red alder
9,700 8,950 8,370 8,400 8,860
Heating values for the wood of some NW species in BTU/ovendry lb. (Ince 1979).
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Cedar Waste Test Results Load # Date Days Cords Net Wt Tons/cord Tons/day
1 4/12/05 7 12 35,420 1.48 2.53 2 4/23/05 5.5 9.5 27,740 1.46 2.52 3 5/04/05 7.5 12.75 32,480 1.27 2.17 4 5/16/05 7.5 12.75 34,780 1.36 2.32 Average Four Loads 6.9 11.8 32,605 1.39 2.38
Load # Date Truck $/ton Hog $/ton
Waste $/ton Waste $/cord %Waste $/Gross Sales
1 4/12/05 ($11.29) ($2.00) ($13) ($20) (2.48%) 2 4/23/05 ($14.42) ($2.00) ($16) ($24) (3.04%) 3 5/04/05 ($12.32) ($2.00) ($14) ($18) (2.31%) 4 5/16/05 ($11.50) ($2.00) ($14) ($18) (2.33%) Average Four Loads ($12.27) ($2.00) ($14) ($20) (2.54%)
Waste cost is $14/ton or > 2% of Gross Sales!
If mills put in their own hogs:
• Delivered hog fuel = $11/GT ~= trucking cost
But mills will need:
• Hog, conveyors, conversion = $30-50,000
• Truck, 2 vans = $30-50,000
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Comparisons of debt burden (monthly payment) for 5 year notes
Interest rate Principle Monthly Payment
6.5% $50,000 $978.31
6.5% $100,000 $1956.62
10% $50,000 $1062.36
10% $100,000 $2124.71
The least payment is $1000/month.
Could be over $2000/month.
A large expense for small businesses.
Other options:
• Centrally located hog. Possible but is there enough to support it? ~20,000GT/year. @$11/GT = gross $220,000.
• Centrally located burner. Same question. Burners start at $100,000. And who would do it? A coop!?
• Burner upgrades to compliance. Not likely.
• Pellet manufacture. Insufficient volume of material.
• Mulch and animal bedding. No wholesale market.
• Cedar oil. Chips would better.
• Chips. Not effectively recoverable.
All Options Require Hogging Capabilities All Options are Expensive
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Existing Choices are not encouraging…
A Broader View is Needed!
Review what we know?
>$10million industry.
>$7million taxes.
>50 jobs.
>20,000 GT/year of cedar waste.
@$11/GT = $220,000. But actually worth more!
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Renewable Energy is a local-to-global priority.
Life Cycle Analysis shows that wood is better!
Source: Rickter 1998
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Fuel Oil Natural Gas Coal Wood
$/Million Btu $2.25/MM Btu $5.60/MM Btu $1.27/MM Btu $1.20-2.70/MM Btu
And Cheaper?!
Source: Bergman & Zerbe. 2004
$10-$23/GT
99% of Washington carbon dioxide is from fossil fuel
Source: McNeil Technologies, Inc. 2003.
wholesale price
retail price
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Source: Wood-Chip Heating Systems
$2.46/gallon - 01/06
$1.55/ccf – 01/06
Wood cost assumption $25-30/green ton
Darby School, Montana The system consists of a burner, a boiler, a feed system, a fuel storage facility and a distribution system. The total cost for the system, including replacing and upgrading some portions of the existing distribution system, is approximately $870,000 for a 118,000 square foot building complex. $7.37/sq ft – 1000 GT/year - >$50,000 in fuel oil savings the first year
Fuels for Schools
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3 MW ~150 green tons/day (6-7 chip vans).
$4,000,000 Capital Cost
Biomass-to-energy A National energy priority
Less greenhouse gases
Eliminate line loss
Reduce landfill pressures
Reduce reliance on foreign oil
Retain and create jobs
More…
There are two large sawmills (~8 vans/day) plus several small mills.
Other sources of wood biomass are available also.
…And! More Local Fuel is Available!
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Tens of thousands of acres of second growth need thinning.
Transportation isolation makes hog fuel uniquely available. Feed stock for distributed rural renewable energy should be considered as a resource not as a waste problem. Elimination of line loss saves on energy and infrastructure costs. Small forest products industries should be viewed as important contributors of affordable and needed biomass.
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Biomass‐to‐EnergySolutions
EnergyIndependenceforFutureGenerations
A Feasibility Study has been completed with Four Options Considered
1. Biomass Boiler In-town Solution
2. 1.0 MW In-town CHP Solution
3. 1.2 MW Industrial Park CHP / Mill Solution
4. 3.2 MW Industrial Park CHP / Mill Solution
Two Options are being pursued: A city-owned heating system and a privately-owned Combined Heat and Power (CHP) facility.
Biomass‐to‐EnergySolutions
EnergyIndependenceforFutureGenerations
Biomass Boilers:
• Provide value for hog fuel
• Low-cost heat for public buildings
• Energy savings > $100,000/year
• 1 job
3.2 MW Industrial Park CHP / Mill Solution:
• Provide value for hog fuel
• Sell steam and electricity to sawmill
• 5 jobs
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Meanwhile the mills try to hang on:
1 mill closed
10 mills struggling
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Simulation of Biomass Pelleting Operation Sudhagar Mani, Ph.D.
Bioenergy Conference & Exhibition 2006 Prince George
May 31, 2006
Department of Chemical & Biological Engineering University of British Columbia
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Presentation Outline
Introduction
Biomass pelleting operation Simulation model development
Model results
Conclusions
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Pelletization Process
Biomass pelletization is a process of reducing the bulk volume of the material by mechanical means for easy handling, transportation and storage.
• Product - pellets
Pelleting Process
60 – 150 kg/m3 (4-10 lb/ft3) ~650 kg/m3 (40 lb/ft3)
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Why to Pelletize Biomass?
Biomass - renewable fuel High moisture content
• 80–50% (wb) moisture content
Non -uniform in particle size Low bulk density
• 60 kg/m3 for loose straws • 150 kg/m3 for sawdust
Low energy density per unit volume High transportation and storage cost Difficult to feed to the gasifier/combustor
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Advantages of Pelletization
6 mm
10 -12 mm Uniform in size, density and moisture content
Moisture content: 6 to 8% (wb)
Easy to transport, convey and feed using the existing systems
High heating value: 18.5 GJ/t
Export commodity - >70% pellets produced are exported to Sweden, Denmark, Netherlands, USA
Domestic heating, animal bedding, power generation
Samson et al., 2005 – Critical Review in Plant Science
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Biomass Pelleting Operation
Biomass residues collection
Transport to pelleting plant
On-site residue storage
Residue screening Drying Grinding Pelleting
Cooling Screening Storage Transport
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Objectives
To develop a systematic simulation model for a biomass pelleting process to calculate pellet production cost, energy use and machinery requirement
To conduct sensitivity analysis on raw material cost, plant size and process modifications
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Model Assumptions
For a base case
Biomass unit size – 25 tonne
Feedstock – Sawdust at 45% mc
Feedstock transport distance – 5 km
Pellet plant size – 6 t/h
Operating hours – 7500 h/y
Dryer fuel – dry biomass/shavings
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I/O of Biomass Pelleting Simulation Model
Biomass Pelleting Simulation Model
Feedstock Condition, Equipment Performance (power, capacity, Efficiency etc.), Unit cost
Cost of pelleting Energy use Labor & equipment use
Model Input Model Output
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Model Analysis
Millres idue
TruckT ransport
Drying
G rinding&P elleting
Totalenergyconsumption
B iomass P ellets
C ooling&S creening
Dieselfuel
B iomass fuel
E lectricity
E lectricity
Energy Analysis
Economic Analysis
Biomass Pelleting Operation
Capital cost (US$)
Operating cost (US$)
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EXTEND simulation model interfaced with spreadsheet
3V 1 2 L W
F
TCR
Receive
R C T
Send1 2 3
Rand
Set A(5)
LoaderTruckBulk
NL
NT
#F
nExit
#
TCR
Receive
TCR
Receive
PelletingProcess
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Energy Consumption of Pelleting Process
Operations MJ/t of pellets % change
Feedstock Transport 57.53 1.44 Drying 2825.54 70.96 Size reduction 311.14 7.81 Pelleting 455.70 11.44 Cooling 74.97 1.88 Screening 80.85 2.03 Miscellaneous 176.28 4.43 Total 3982.01 100.00
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Pellet Production Cost
4.73
10.30
0.953.310.34
0.16
12.74
0.262.77
4.73
0.953.31
0.340.16
12.74
0.262.77
0
5
10
15
20
25
30
35
40
Pelle
t Pro
ducti
on co
st (U
S $/t
)
with drying without drying
MiscellaneousequipmentLand use & building
Personnel cost
Screening
Pellet cooler
Pellet mill
Hammer mill
Drying operation
Transport cost
$35.57
$25.26
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Pelleting Cost Distribution Transport
cost13%
Drying operation
29%
Personnel cost37%
Land use & building
1%
Pellet cooler
1%
Packing5%
Pellet mill9%
Hammer mill3%
Screening0%
Pellet Storage
0%
Miscellaneous
equipment2%
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Pelleting Cost vs Plant Size
0
15
30
45
60
75
90
0 4 8 12 16Plant capacity (t/h)
Pelle
t pro
duct
ion
cost
(US$
/t)Total costCapital costOperating cost
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Pellet Production Cost vs Feedstock Cost
0
25
50
75
100
125
150
0 10 20 30 40 50 60 70 80Raw material cost (US$)
Pel
let p
rodu
ctio
n co
st
(US
$/t )
With drying process
Without drying process
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Case Study- MPB wood into Pellets
MPB infested wood
Felling & Skidding
Whole tree chipping
Transport to Pellet plant
Grinding & Pelleting
Cooling & Screening
MPB pellets
Wood chips
15% mc
10 km
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MPB Wood Pellets
Operations Production cost*, US$/t of pellet
Felling 4.88 Skidding 4.46 Whole tree chipping 3.94 Chip transport (10km round trip) 11.91 Storage (piling) 7.16 Pelleting without drying 20.50 Total 52.85
*based on a pellet plant capacity of 6 t/h
$32.35
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Conclusions A simulation model for biomass pelleting process was
developed using extend simulation platform interfaced with a spreadsheet.
Total energy required to produce a tonne of wood pellet is
about 4 GJ, which is about 22% of the wood pellet energy.
Cost of producing wood pellet from mill residues at 45% moisture content alone was about $36/t of pellets with an annual production rate of 45,000 t/y.
MPB infested wood into pellets costs about $53/t of pellets
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Current Projects at UBC
GIS based simulation and modeling of agricultural and forest biomass supply logistic systems
Pelletization characteristics of MPB infested wood
Combustion characteristics of wood pellets for Green house applications
Life cycle analysis of bioenergy systems
Investigations on handling and storage of wood pellets
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Contact Information
Biomass and Bioenergy Research Group Department of Chemical & Biological
Engineering University of British Columbia 2360 East mall, Vancouver BC V6T 1Z3 Ph: 604 827-3413 Contact: Drs. Shahab Sokhansanj/Xiaotao Bi
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Thank you
Biomass Pelleting Process