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Cogeneration with
waste biomass
Presentation at Bioenergy Australia National
Conference, November 2013
by
Colin Stucley, Enecon Pty Ltd
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Cogeneration with waste biomass
• Introductions & acknowledgements.
• Cogeneration alternatives.
• Case study in Victoria
o Background to project.
o Assessing design alternatives.
o Construction.
• Summary.
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Enecon: Over 40 bioenergy studies, reports & projects since 1998
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Acknowledgements
• Australian Tartaric Products.
• Victorian Government – Regional Dev’t Victoria.
• Australian Industry Group.
• Bono, gTET.
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• Combined production of heat and power (“CHP”)
• Greater energy recovery may lead to better economics
• MUST have long-term use for heat
Cogeneration may arise from a wish to:
1. Use excess heat to produce power
2. Make productive use of “waste” heat from power unit
Cogeneration – alternative approaches
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1. Use of excess heat to produce power
• Analyse the heat and power needs on site
• Is the heat load variable either daily or seasonally?
• Is excess feed available?
• Can we generate power at times of low heat use?
• May be alterations to heat plant for power generation
Cogeneration – alternative approaches
Biomass
feed Biomass
combustion
or
gasification
Power
unit
Electricity
Process heat (steam, hot oil, hot water)
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2. Productive use of waste heat from power unit
• Different heat and power needs to previous example
• Initial focus is on power generation
• Heat recovery will impact on power generation efficiency
• Heat recovery may impact on equipment selection
Cogeneration – alternative approaches
Biomass
feed Biomass
combustion
or
gasification
Power
unit
Heat (steam,
hot oil) or gas Electricity
Process heat (steam, hot
oil, hot water)
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• Bioenergy plants have significant capital costs
• They should be run continuously
• Feed may be in excess of site energy needs
• Larger bioenergy plants offer economies of scale
• External customers generally offer lower prices
than internal customers.
What is the optimal size for a plant ?
Cogeneration – plant sizing
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Case study - Australian Tartaric Products
Pty Ltd
• Process plant near Mildura in Victoria.
• Feed: grape marc, up to 50,000 tpa.
• Products: tartaric acid, tartrate, ethanol.
• Continuous operation with two main seasons.
• Spent marc is major by-product.
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ATP – biomass feed
Spent grape marc: • High moisture • High ash
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ATP: energy use
• Process steam, for diffuser and distillation.
• Heat for dryer.
• Electricity for motors and lighting.
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ATP: previous energy generation
• Steam - via two on-site boilers, fired by LPG
and fuel oil.
• LPG – also used to heat air for drying.
• Electricity - bought from grid.
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Schematic for previous energy system
Fuel oil-
fired
boiler
Cold water
Low Pressure
Steam
LPG
Heat and power requirements
for the process plant
LPG-fired
boiler
Fuel Oil
Electricity from grid
For air heating
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New energy system – the opportunity
Increasingly competitive marketplace.
Energy costs rising… can they be reduced?
• Consider a bioenergy system fired on spent marc
to replace fossil fuels and grid electricity
• Italian parent company already using spent marc
(superheated boiler with steam turbine).
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• Spent marc - wet, and high inorganics.
• ATP’s site has two distinct operating “seasons”.
• Operability - bioenergy plant must not
compromise process plant operation.
• Water - low availability and low quality.
• Operation - attended or unattended?
• Electricity export ?
New bioenergy system – the challenges
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Design options – (1) heat production
Steam system ?
• Low pressure saturated steam for process.
• How to generate electricity?
• How to pick up other thermal loads in plant?
Hot oil system ?
• No history of hot oil use on site. Is it easy to operate?
• How will it provide LP steam and thermal loads?
• Benefits for electricity generation?
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Design options – (2) power generation
Steam turbine ?
• High pressure and superheat for good efficiency
• Issues with new, higher water specification for site
Steam engine ?
• Availability of supplier
• Maintenance issues
Organic Rankine Cycle unit ?
• Offer considerable flexibility in size and operation
• Limited experience in Australia
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Organic Rankine Cycle units
• Package units for electricity generation
• Can also provide useful heat.
• Turbine, using organic liquid instead of steam.
• Wide range of input & output temperatures.
• Suppliers in Europe, USA, Australia.
• Range <200 kWe to >20 MWe, plus heat.
• Flexible, unattended operation possible.
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Pratt & Whitney “Pure Cycle” ORC unit at
Gympie Timbers, Qld
Organic Rankine Cycle (small scale)
gTET ORC unit at Reid Bros Timbers, Vic.
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Turboden ORC unit
Organic Rankine Cycle (large scale)
Ormat - 26 MW geothermal ORC plant in New Zealand
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Cogeneration system selected for ATP
Heat and power requirements
for the process plant
Flue gas
Spent
marc
Biomass-
fired boiler
(10 MWth)
ORC power
unit
(600 kWe gross)
Electricity to plant
LP steam
Ash
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Construction at ATP’s site
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Boiler construction
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Boiler construction
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Boiler construction
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ORC unit
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ORC unit
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ORC unit
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Summary
• Waste biomass offers alternative to fossil fuels.
• Cogeneration allows optimal use of bioenergy.
• Analyse customer needs.
• Need return on capital and operability.
• Analyse feed characteristics.
• Consider process alternatives: steam, hot oil.
• Consider size alternatives: economy of scale
versus product values to different customers.
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Thank you – questions?
Speaker details: Colin Stucley, Director Enecon Pty Ltd - 651 Canterbury Rd - Surrey Hills, Vic. 3127 - AUSTRALIA
Tel. 61 3 9895 1250 - www.enecon.com.au