ISSCT Trash utilization at sugarcane mills · Trash utilization at sugarcane mills ... steam...

SULEIMAN HASSUANI 1

ISBUC 2009ISBUC 2009

ISSCTISSCT


CTC CTC -- CENTRO DE TECNOLOGIA CANAVIEIRACENTRO DE TECNOLOGIA CANAVIEIRA

Trash utilization at sugarcane millsTrash utilization at sugarcane mills

A path to advanced biomass power generationA path to advanced biomass power generation

Suleiman Hassuani

[email protected]

29 June 2009

SULEIMAN HASSUANI 2


BAGASSE

BIOCHEMICALCONVERSION

COMBUSTION

GASIFICATION

EE/STEAM

ETANOL

STEAM / EE

FUELSFERTILIZERS

NEED OF ADDITIONAL BIOMASS

Energy conversion alternatives

TRASH

ProductsProducts for for thethe sugarcanesugarcane sectorsector

� Electricity

� Fuels – Etanol, Diesel, DME, Gasoline

� Fertilizers – NH3

SULEIMAN HASSUANI 3


How to increase electricity generationHow to increase electricity generation

1. Improve energy generation efficiency

� advanced technologies

2. Increase fuel availability

3. Reduce process steam/energy

consumption

SULEIMAN HASSUANI 4


JUICEEXTRACTION

MILL PROCESS

Dryer

Gasifier

Gas cleaning

Gas turbine

Hot gasesgenerator

Heat recoverysteam generator

EE

EEE

bagasse

gas

gas

Condensingturbo

generator

gas

steam

bagasse

Turbogenerator

Advanced Technologies Advanced Technologies –– sugarcane mill integrationsugarcane mill integration

Gasification Gasification -- full integrationfull integration

steam

� Mill is totally dependent on energy for its processes.

� Energy production depends on gasification process.

� System is quite risky for integration at initial stages of technology development and commercialization.

SULEIMAN HASSUANI 5


bagasse

MILL PROCESS

Boiler

Turbogenerator

STORAGE

ee

steam

vapor

bagasse

JUICEEXTRACTION � Increase in energy export is

made through high pressure boilers

� Energy export depends on process consumption

� Reduction in process consumption decreases energy export

� Electricity generation only during the season

Advanced technologies sugarcane mill integrationAdvanced technologies sugarcane mill integration

Pure cogenerationPure cogeneration

SULEIMAN HASSUANI 6


bagasse

Boiler

Turbogenerator

EE

steam

Condensingturbo generator

EE

bagasse

JUICEEXTRACTION

STORAGE

� The increase in energy export is made through:

1. The use of higher pressure boilers.

2. Reduction of process steam consumption

3. Increase efficiency of mechanical energy generation - electrification

4. Use of condensing steam turbo generators

5. Increase in the consumption of biomass (bagasse)


Cogeneration & condensingCogeneration & condensing

MILL PROCESS

steam

SULEIMAN HASSUANI 7


bagasse

Boiler

Turbogenerator

EE

steam

steam

+ trash


Cleaning station bales

bagasse

JUICEEXTRACTION

STORAGE


Cogeneration & condensing with trashCogeneration & condensing with trash

MILL PROCESS

� The increase in energy export is made through all the previous conditions plus:

� Use of trash as additional renewable fuel

� Possibility to generate electricity year-round

EEEEEE

SULEIMAN HASSUANI 8


bagasse

Boiler

Turbogenerator

EE

steam


JUICEEXTRACTION

+ trashbagasse

GASIFICATION


Gasification with trashGasification with trash

STORAGE

MILL PROCESS

steam


EEEE

SULEIMAN HASSUANI 9


bagasse

Boiler

Turbogenerator

EE


Dryer

Gasifier

Gas cleaning

Gas turbine

Hot gasesgenerator

Heat recoverysteam generator

eeEEEE

bagasse+trash

gas

gas

Condensingsteam generator

gás

steam

JUICEEXTRACTION

STORAGE


Gasification with trashGasification with trash

MILL PROCESS

steam

steam

+ trashbagasse

Use of trash willprobably be necessary

to guarantee:year-round generation

& gasificationfeasibility

SULEIMAN HASSUANI 10


ComparisonComparison ofof technologiestechnologies

PotentialPotential ofof electricityelectricity exportexport

Bagasse 62 bar

Bagasse 62 bar+ 50% trash 45% mc

Gasification stand alonebagasse+50% trash 45%mc

Gasification integratedbagasse+50% trash 45%mc

Gasification integratedbagasse+70% trash 15%mc

0

50

100

150

200

250

300

250300350400450500

Process steam consumption (kg/tc)

Esp

ecif

icel

ectr

icit

y ex

po

rt (

kWh

/tc)



25Tops

1724Green leaves

8171Dry leaves

drywet%For each 1 t of cane stalks there is:

140 kg of dry trash (14%)

Trash potential



First step towards trash accessibility

Pre harvest burning elimination impacts

� Field impacts

� Increase in harvester losses

� Reduction in harvester capacity

� Difficulties in field operations

� Changes in the ecosystem: herbicide effect, organic matter, soil moisture, etc.

� Industry impacts

� Increase in vegetal impurities

� Increase of soil in the process

� Reduction in milling capacity

� Increase in maintenance

� Process control difficulties



Trash available in the field

20 to 25% of the trash goes to the mill

with the cane

BAGASSE Cane fiber + trash

with the cane

Conventionalunburnedharvesting

75 to 80% of the trash stays in the field



Trash recovery

Questions that should be answered

� How to collect the trash?

� How much trash should be collected?

� What is the impact of trash recovery in the field? – agronomy and equipment performance.

� What is the trash cost?

� What is the necessary industrial process?

� What is the impact in the industry?

� What are the gains???



Saga of trash recovery effortSaga of trash recovery effort

Baler & Hay harvester – recovery from the soil

� Excessive number of equipment

� Traffic in the field

� Difficulties in management

� High humidity if it rains after harvesting

� Time limitations before cane sprout

� Excessive soil with trash (5 a 10%)

� Several maintenance problems.

� Baler: needs unbailing and trash shredding

� Hay harvester: no need of shredding but soil is incorporated to trash

� Low trash moisture content (10 – 15%)



� Operational problems

� Reduced harvester reliability

� Need to increase harvester power

� Reduced harvester performance

� Difficulties in controlling vegetal impurities in the cane

� Reduced trash density


Trash recovery from the harvester




Harvesting cane and trash – Partial Cleaning

Objective: Make feasible the best alternative to collect trash and cope with field operations



Primary extractor

Secondary extractor

Cropdivider

Base cutter

Chopper

Topper

Roller feeding trainFinned roller

Knock down roller

Elevator

REDUCED SPEED

TURNED OFF


Harvesting cane and trash – Partial Cleaning



Harvesting with reduced fan speed

TRASH in the field TRASH with the cane

BAGASSE Cane fiber + leaves

and tops not separated

TRASHLeaves

separated at the Cleaning Station

50% 50%

Harvesting cane and trash

Partial Cleaning



Harvesting with reduced fan speed

TRASH in the field TRASH with the cane

BAGASSE Cane fiber + leaves

and tops not separated

TRASHLeaves

separated at the Cleaning Station

50% 50%

• Losses reduction• Fuel consumption reduction• Increased performance

• Agronomic benefits• Weed control• Erosion control

• Truck load reduction• Need of trash separation at mill• Need to process the trash

Partial Cleaning

Impacts



Trash and soil separation from the cane at the industryTrash and soil separation from the cane at the industry

Cleaning station systemsCleaning station systems

Cane and trash

Air stream

Trash and soil

capture chamber

Feeding table separation

Air s

trea

m

Trash and soil capture chamber

Cane and trash

Between conveyors separation



Trash processing

Soil removal and trash shredding

ROTARYSCREEN

SHREDDER



• Shredding by cutting

• Operates even with high moisture

• Need of knives sharpening

Trash processing

Shredder



Trash processing

Shredder



18,0

17,0

17,0

Higher heating value (dry)

MJ/kg

3.10012,915Trash 1

1.7107,250Bagasse

2.2509,435Trash 2

kcal/kgMJ/kg

Lower heating valueMoisture content

(%)

Heating Value

48

45

O

-

0,1

S

-0,45,846Bagasse

0,20,66,448Trash

ClNHCUltimate Analysis* (%)

83143Bagasse

75169Trash

Volatile matterFixed CAshProximate Analysis* (%)

Trash as a fuel

Characterization of sugarcane trash

*Dry basis

*Dry basis



Temperatures (oC)

13301260Bagasse

12601160Trash

FluidBeginning of

ash deformation

Trash as a fuel

Ash fusion

Whole trash bale burning in furnace

Trash high mineral impurities content



Trash as a fuel – year round generation

Biomass storage

Traditional bagasse storage systems



� With trash - Additional fuel

� Define generation strategy – season or year-round generation

� Impact on equipment and storage needs

� Bulk uncovered storage

� Soil preparation

� Location

� Piles form and size

� Equipment

� Need of covered storage: 7 days storage??

� Trash has to be burnt immediately, mixed to bagasse

Trash as a fuel – year round generation

Biomass storage

STORAGE BECOMES A RELEVANT ISSUE



� Increase biomass by cane stalks fiber increase

� Parameters under study

� Impact on milling/diffusers capacity

� Impact on sugar extraction

� Impact on bagasse quality

� Impact on energy consumption of equipment

� Feasibility analysis

� Fiber optimized range

� Definition of new “contribution margin” equation

� Varieties development

Energy cane

Sugarcane high fiber content varietiesSugarcane high fiber content varieties



Steps for the generation of considerable amounts EE Steps for the generation of considerable amounts EE

ConclusionsConclusions

0

50

100

150

200

250

300

250300350400450500

Process steam consumption (kg/tc)

Esp

ecif

icel

ectr

icit

y ex

po

rt (

kWh

/tc)

� Use high pressure steam boilers (above 65 bar)

� Use of steam extraction & condensing systems

� Electrification of mechanical power

� Reduce process steam consumption

� Use additional biomass: trash and cane fiber increase

� Use of advanced technologies –gasification combined cycle

Costs versus gains will define the technologies to be applied



The endThe end

THANK YOU!

Suleiman Hassuani

[email protected]

CTC – Centro de Tecnologia Canavieira

www.ctc.com.br

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ISSCT Trash utilization at sugarcane mills · Trash utilization at sugarcane mills ... steam...

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