CORPORACIÓN PARA LA INVESTIGACIÓN ENERGÉTICA

SOLAR-THERMAL COFFEE AND COCOA BEAN DRYING SYSTEM

Summary

The project intends to scale up a solar-thermal corn drying system, a pilot project conducted by CIE. The idea is optimizing corn, cocoa or coffee drying processes, partially replacing the use of fossil fuels ( LPG) by solar and biomass energy. The sun's heat will be captured through an innovative system and then will be stored in the ground. Heat from this reservoir warms circulating water, which is pumped by a heat transfer pump, heating air inside a chamber, where grain move on a continuous helicoidal system. Alternatively, residual biomass energy will be produced in a pyrolysis gasification system.

Searching for efficiency, two main areas in the drying system, were defined. One is focused in generating the required heat for drying, reducing LPG consumption and utilizing solar energy; the second is focused in efficiency through a continuous drying system that mechanically keeps grain in motion, exposing it constantly to heat.

For the construction and installation of the systems, sites with grain producer communities, properly organized to improve new technologies, were located.

The system intends to deliver an innovative model of drying cocoa beans and coffee, using renewable energy for obtaining a clean product, in shorter drying timing, without the use of fossil fuels to dry beans. It is about reducing drying costs for small producers benefit as well.

Scope for innovation in terms of technology

The proposed grain drying system based on a corn drying system developed and tested by CIE, is mainly composed by two subsystems identified to be improved: The heat source and the drying chamber.

As explained before, for improving the heat source, a solar heating system with underground storage is proposed.

Technological innovations designed to improve the drying efficiency will be incorporated in the drying chamber. For increasing the system efficiency, we have defined the need to keep the grain in constant and smooth motion increasing grain exposition to heat at a temperature of 40 C°to 60 C°. A cylindrical dryer with a helicoidal net inside, rotating constantly at a speed of 0.3 revolutions per minute, will be constructed.

Since cocoa bean is more brittle and moisture, a conveyor system in a hot air chamber is proposed.

Our Experience

For the last thirteen years, CIE has performed a series of feasibility studies for wind projects like Huascachaca 70MW, El Aromo 70MW, Montecristi 50MW under contract with public institutions like ELECAUSTRO and CELEC EP, and other wind projects with less important results. 2010, 2012, 2012.

Regarding biomass projects, CIE executed successfully the Construction and Operation of a Pilot Plant for Electricity Generation from Residual Biomass, in a partnership with National Institute for Agricultural Research-INIAP. 2010

Synthesis Gas analysis to produce ammonia fertilizers (UREA) utilizing the Gasification Biomass Pilot Plant was performed by CIE under contract with INIAP and the Ministry of Industries of Ecuador. 2012

Research Studies about available biomass resources in four provinces of Ecuador were conducted by CIE in order to define residual biomass energy potential.

CIE elaborated the first Solar Atlas of the country, a tool for photovoltaic farms developers and other productive activities. About 260Mw resulted from this document consultation.

Design, construction and testing of a solar corn drying system which substitutes 100% LPG (liquid petroleum gas) used as fuel in such processes. Instead, our system uses solar energy stored in the ground (geothermal). In Ecuador, 361.347 hectares are dedicated to grow corn, producing 1.5 million tons per year. This production is entirely dried using GLP y diesel, producing global warming and grain and air contamination.

A Biotechnology laboratory created for elaborating the National Catalog of Microalgae with projection to developing food, medicinal and energy crops, while capturing the CO2 of thermal power plants.

One of our strategies to perform investigation on renewable energy in a country with an economy based on the oil exploitation has been to work with governmental institutions.

Project Objective

Introduce tropical crops drying systems (cocoa, coffee, corn, etc.) using renewable energy innovative clean systems: sun, residual biomass.

a. The proposal promotes reduction of LPG consumption in drying, through an efficient continuous system that incorporates the use of solar energy for heat generation.

b. Contrary to what happens in traditional systems, the grain (or beans) comes out cleaner from our system.

c. Solar energy is complemented with residual biomass energy obtained by burning synthesis gas produced through a pyrolysis process.

Beneficiaries

The cocoa drying plant would be located in Puerto Limón to benefit Association of Agricultural Producers La Valencia (58 families). A piece of 1824 m2 land is available for drying activity (30000kg/month of cocoa beans).

For sun drying to reduce the moisture content from about 80% to 25%, (optimal 7%) the beans are spread out under craft greenhouses, on concrete floors. With adequate sunshine, sun drying may take about 5 – 6 days, but if the weather is dull or rainy, it will take longer. This procedure implies hard labor and contaminates beans lowering its quality and price.

The other beneficiary community is AAPROCNOP, 60 members (families), producing a high quality organic coffee but their production is lower than the average of the zone. Drying processes include LPG usage for complementing solar craft systems. The dying is completed in about four weeks, depending on the weather conditions. The zone has a coffee productive potential of 4,000 hectares, currently grassland, eroded soils and short-cycle crops with low economic returns, which are intended to be replaced by organic coffee plantations for economic and social improvement (exportation).

La Valencia. Agricultural Producers Association.

Current procedures…

AAPROCNOP Coffee collection Center

Indirect beneficiaries

The indirect beneficiaries of the Project would be:

1. Local suppliers of materials and services for the implementation of the proposed system. Specifically, manufacturers of equipment and metal working structures.

2. Distributors and final consumers of cocoa and coffee.

3. Central Government. This project contributes to LPG reduction for drying cocoa and coffee beans. LPG subsidy financed by the central government reduction.

4. The Ecuadorian Ministry of Agriculture, (MAGAP). This project contributes to Agricultural Competitiveness and Sustainable Rural Development.

5. The project will generate income for members of cooperatives, increasing access to opportunities arising from the improving economic conditions of their families. Additionally, skills, abilities and knowledge acquired by the direct beneficiaries may be transmitted to members of their families as an effective mechanism for raising and empowerment.

Deliverables

Mainly the following:

a. The final design of cocoa, coffee and corn drying systems.

b. Reports of construction, testing and finally operation of the system.

c. Operation Reports during the drying period. Systematization.

d. The final Project report with its analysis and conclusions.

Expected results

a. Solar energy systems implementation, CO2 emissions eliminated in the process of drying the cocoa and coffee.

b. Incorporation of a heat storage method using ground as heat reservoir, allowing system to operate under not optimal solar radiation conditions.

c. The incorporation of a system using heat generation and a residual biomass gasification process by pyrolysis.

d. The current average cost of drying cocoa and coffee beans is $ 1.5 per 45.36 kg. Through the replacement of LPG consumption it is estimated that producers revenue will be also raised by avoiding industrial LPG procurement ($13.5 per 15kg. All this considering LPG state-subsidized prices.

e. Finally, it is expected to create job openings. And trained people on implementation, management operation and maintenance and replication of the proposed system as well as technical, economic and environmental benefits.

Performance indicators

a. Comparison of LPG consumption per kg of dried cocoa and coffee beans versus the proposed solar-geothermal method (means of verification: control system incorporated in the dryer).

b. LPG consumption decreased (unit of measurement: kilograms, means of verification: LPG purchase invoices).

c. Reduction in CO2 emissions in the cocoa and coffee solar-geothermal drying system compared to the traditional method (Unit of measure: CO2 kg).

d. Reduction in corn drying costs over the current drying (unit of measurement: USD).

e. LPG subsidy avoided (Unit of measurement: Annual cost in USD).

f. Jobs created (Unit of measurement: number of workers, means of verification: employment contracts).

g. Training (Unit of measurement: trained staff, means of verification: evidence of workshops).

Social, Economic and Environmental Impact

This project is characterized by cross-way integrating Technological, Environmental, Social and Economic Benefits. The project has a positive impact on the environment because it avoids emissions generated in the traditional system (LPG). Alternatively, the project uses solar energy for cocoa and coffee drying processes. The proposed Project would contribute to the mitigation and adaptation to climate change. A component, as solar energy and gasification process, added to energy efficiency Improvement in the drying process, contribute to the mitigation of global warming. This project promotes a resilient and independent system.

The project has a direct impact on the socio economic conditions of the beneficiaries. The inclusion of this group of small producers in this process that incorporates renewable energy has a clear purpose of social and economic inclusion. The revenues increase of people promotes them as active traders.

Specifically, the project is aligned with the development of institutional capacity, it promotes public-private partnerships and provides the environment as a cross element. It is noteworthy that the project is also consistent with the objectives and policies of the Ecuadorian National Plan for Good Living (Goal 4).

Scale of the project (sizing)

The project is defined as an up grading to the system developed by CIE for drying corn. The objective is to establish possibilities for using it on a larger scale for the benefit of farmer communities. The intention is to work with two or three rural communities producing cocoa, coffee and corn. After one year performance, analyze results and establish real efficiency rates, to implement improvements to the system in order to allow the desired objectives achievement. The technology can be replicated and adapted to other locations and conditions where similar needs for drying capacity have been detected.

Replicability

The proposed model has the following main components:

a. A heat generating system by solar means.

b. A heat generating system using residual biomass.

c. A heat storage system.

d. A continuous drying system.

Each one of these points must be analyzed and adjusted according to the specific conditions in the geographic location of the dryer. Areas, under varying solar radiation conditions should be adjusted to allow the solar collector generate expected heat. This in turn implies an adjustment in the area of heat storage. When necessary, biomass energy (Syngas) will be used.

Furthermore, the continuous drying system is adjustable by regulating the heat generated and the rotational length and speed. This makes it possible to increase or decrease the capacity of the dryer according to the needs of the user and the volumes handled.

Technical and financial sustainability

This project is planned to last 15 years. Technologically the system allows a reduction in LPG consumption up to 100%. About 120 families produce 115 tons of coffee/year in this sector. Humidity, at this point is about 57%. Drying processes currently include craft systems complemented with a high percentage of LPG usage. The coffee price is $180 to $300 per sack (45.36 kg). Super premium coffee reaches up to $600 per sack.

The cocoa price with humidity higher to 15% varies depending on the moisture. The average humidity of cocoa beans is 80%. Price and humidity are closely related ($ 9 per 45.36 kg sack). Same weight of dried cocoa is $100.

The project, according to its designed capacity will be able to raise small producers income, which allows a return on investment in approximately 3.4 years. Since during the first year the system will be in the experimental stage it is estimated that the return on investment for this project is approximately 4.4 years.

The long-term in the project aims to increase drying capacity and be replicated in 30 cacao producers associations registered in Santo Domingo de losTsachilas and 4 coffee producers associations in Nanegalito, Pichincha.

Methodology and main activities

The project consists of three phases clearly identified.

a. Planning and Construction. The objectives and indicators of the project will be defined in advance and proper engineering will be developed. The dryer is constructed jointly with the manufacturer and later the system is moved to its final location. At the defined site, the dryer is assembled and all testing mechanical operation thereof is performed. The elements of the solar collector system will be designed and constructed, including the heat recovery pump. The planning and construction should be given in the first 6 months of the Project.

b. Dryer operation. It is coordinated with the community of producers. Control mechanisms and relevant obtained information are set during system operation. The dryer operates during cocoa and coffee harvest months.

c. Analysis and feedback. During Operation and once we have the real information about System Performance, the Information is analyzed for defining action plans to improve efficiency to accomplish or surpass the objectives previously established.

d. The implementation and testing term of the project is estimated in 24 months after receiving allocated funds.

Implementation Strategy

The project implementation will be such to ensure proper operation and information gathering. First we will work together with the builder of the dryer (metalworking) and equipment suppliers for the correct construction. Once the construction of the dryer is completed, performance tests will be conducted. Then we have to install the dryer on the previously assigned site. Prior to the operation of the dryer training will be provided to the small producers about the maintenance and operation of the system as well as correct information gathering. Once communities are trained, function tests with cocoa and coffee beans will be performed in small quantities to ensure proper system operation. All this must be done during the first four months of the project.

Once the dryer is operating in full capacity for four months, adjustments and corrections to the system will be performed.

Once the harvest season is finished, a thorough analysis of the system will be conducted for final report submission.

Forecast and Potential Risks

It is important to adjust the periods of harvesting and drying of cocoa and coffee in Ecuador to engineering, procurement and installation of the system.

We must perform a thorough training to beneficiaries about the management, operation and maintenance of the dryer to ensure the system operates at installed capacity. Effective monitoring Information will establish appropriate corrective actions to keep the system operating.

Co financing

It has come to establish a commitment to the La Valencia and AAPROCNOP small cacao and coffee Producers Associations, the first one in Santo Domingo de losTsáchilas and the second one in Nanegalito, Pichincha. They are committed to contribute with the 20% of the total cost of the project. This contribution will be through the provision of suitable places for the continuous dryer implementation, space for the solar collectors, the labor for installation of equipment and personnel needed for the operation, and a cash contribution to acquire equipment if needed.

BUDGET ANALISYS (Two years)

US$

Human resources

54000

Alfredo Mena (Director)

20000

Esteban del Hierro (Agricultural Engineer)

6000

Alejandro Egüez (Project Economist)

2000

Lucía Re (Project coordination)

15000

Luis Rosero (Agricultural Engineer)

4000

Eduardo Pachano (Construction manager)

7000

Travel and lodging

5000

Travel to project sites

5000

Equipment and materials

249300

Engineering design

15000

Solar panels

40000

Transportation

4000

Panels supports

12000

Buried pipe

5200

Geothermal heat pumps

15000

Biomass gasifiers

30000

Air blowers

4500

Drying equipment

75000

Biomass pelletizing equipment

23000

Measure and control systems

5000

Electricity supply

7000

Soil excavation and backfill

8000

Wire protection fence

5600

Other direct costs

11000

Assemblymonitoring

5000

Training

6000

Indirect costs

112500

Land use (24 months)

24000

Payment of electricity, water, etc

4500

Grain handling

24000

Administration, accounting and auditing

60000

Suma

431800

Proponent contribution (20%)

86360

Zayed contribution award

345440

ANNEX

Support letters from the Agriculture Ministry and Small Producers Association.

1