BIOMASS ENERGY SYSTEMS FOR F&B INDUSTRY: CASE STUDIES IN AN INDONESIAN PERSPECTIVE

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1 BIOMASS ENERGY SYSTEMS FOR F&B INDUSTRY: CASE STUDIES IN AN INDONESIAN PERSPECTIVE Kevin Vandewalle 27 Sep

2 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

3 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

4 VYNCKE IN A NUTSHELL FAMILY OWNED 4 th GENERATION COMPANY

5 VYNCKE IN A NUTSHELL HISTORY

6 VYNCKE IN A NUTSHELL BIOMASS TO CLEAN ENERGY Indonesia

8 VYNCKE IN A NUTSHELL ENERGY MEDIA STEAM (5 80 TPH) HOT WATER ( MW t ) HOT GAS (1 100 MW t ) THERMAL OIL (1 30 MW t ) ELECTRICITY ( MW e )

9 VYNCKE IN A NUTSHELL SOLUTIONS

10 VYNCKE IN A NUTSHELL OUR PLAYING FIELD WOOD FOOD & AGRI RENEWABLES

11 MARKETS WOOD

12 MARKETS WOOD

13 MARKETS FOOD & AGRI

14 MARKETS FOOD & AGRI

15 MARKETS RENEWABLES

16 MARKETS RENEWABLES

17 VYNCKE IN A NUTSHELL ENERGIZING THE INDUSTRY

18 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

19 TECHNOLOGY BIOMASS : BALANCING THROUGH EXPERIENCE

20 TECHNOLOGY BIOMASS A FUEL COMPARISON

21 Burner Grate TECHNOLOGY BIOMASS COMBUSTION TECHNOLOGY SELECTION Ø 150 Ø 50 Ø 5 Ø 3,15 Ø 1 Ø 0,315 Suspension combustion

22 TECHNOLOGY THE ART OF MAKING FIRE WHAT?

23 TECHNOLOGY THE ART OF MAKING FIRE A COMPARISON

24 TECHNOLOGY THE ART OF MAKING FIRE A COMPARISON FLUIDIZED BED TRAVELLING GRATE STEPGRATE FUEL FLEXIBILITY STRICT FUEL PREPARATION CONSTANT PARAMETERS REQUIRED (FUEL SIZE / DENSITY / CHEMICAL) VARIABLE MOISTURE CONTENT ACCEPTABLE STRICT FUEL PREPARATION CONSTANT PARAMETERS REQUIRED (FUEL SIZE / DENSITY / CHEMICAL) DIFFICULTIES TO COPE WITH VARIABLE MOISTURE VARIABLE FUEL SIZE ALLOWED VARIABLE FUEL DENSITY ALLOWED VARIABLE FUEL COMPOSITION MOISTURE LIMIT 60% EFFICIENCY HIGH > 90% ON NCV LOW > 75% ON NCV HIGH UNBURNED WITH VARIABLE FEEDSTOK HIGH > 85% ON NCV AVAILABILITY LIMITED ON AGRO FUELS LIMITED ON AGRO FUELS > 8000 h AGGLOMERATION DEFLUIDISATION REQUIRED MANUAL SHUTDOWN & REMOVAL MANUAL REMOVAL WATERCOOLED: LOW AGGLOMERATION EXTRACTION BY AUTOMATIC DEASHING WEAR & TEAR FLY ASH > 85% FG SPEEDS > 25 m/s RESULT: BOILER ABRASION (Si) HIGH ASH CARRY OVER FLY ASH < 30% FG SPEEDS 5 m/s POWER CONSUMPTION VERY HIGH LIMITED LIMITED

25 TECHNOLOGY THE ART OF MAKING FIRE IN DEPTH! Each COMBUSTION STEP needs different grate speed and air flow - Adjustable stroke length and velocity per zone - Adjustable air flow per zone GRATE COOLING DECOUPLED FROM AIR SUPPLY - Air : combustion - Water : cooling Allows optimal air flow settings for - combustion - CO/NO x control Lower flue gas flow / losses - Higher EFFICIENCY WATER PROTECTS THE GRATE - Longer lifetime - Avoid cracks and hot spots - Thermal expansion 5 % 9 %

26 TECHNOLOGY BOILER SELECTION FOR THE F&B INDUSTRY

27 TECHNOLOGY BOILER SELECTION A COMPARISON COMBI BOILER BIDRUM BOILER COMBUSTION ROOM WATERCOOLED ADIABATIC REFRACTORY LINING LOW MAINTENANCE WATERCOOLED / CONDUCTIVE / CASTABLE HIGH MAINTENANCE ADIABATIC / INSULATOR / BRICK WALL FOULING LOW - 3 EMPTY PASSES HIGH - 1 PASS WITH INTERNAL HEAT EXCH ONLINE CLEANING AUTOMATIC CLEANING FOR HEAT EXCHANGERS NO AUTOMATIC CLEANING STEAM VOLUME HIGH (FIRE TUBE STEAM DRUM) LOW (BI-DRUM) HEAT LOSS LOW HIGH

28 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

29 Steam Consumption [kg/h] RULES OF THUMB HOW TO SIZE THE BOILER CAPACITY 11,000 STEAM LOAD kg/h vs. % operating time 10,000 9,000 8,000 7,000 6,000 5,000 OPTIMAL BIOMASS BOILER SIZING 4,000 3,000 2,000 1, % 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% % % of operating time

30 RULES OF THUMB BIOMASS USAGE VS STEAM OUTPUT BIOMASS SOURCE NCV (kcal/kg) 1 T FEEDSTOCK VS T/H STEAM WOOD PELLETS 4,000 kcal/kg 5.5 ton/h PALM KERNEL SHELLS 3,800 kcal/kg 5.3 ton/h COCOA SHELLS 3,800 kcal/kg 5.3 ton/h RICE HUSKS 3,000 kcal/kg 4.2 ton/h WOOD CHIPS 2,500 kcal/kg 3.5 ton/h SPENT COFFEE GROUNDS 2,000 kcal/kg 2.8 ton/h EMPTY FRUIT BUNCHES 1,600 kcal/kg 2.2 ton/h

31 RULES OF THUMB COST OF ENERGY vs. AVAILABILITY! TYPE OF FUEL FUEL PRICE NET CAL VALUE PRICE / TON OF STEAM NATURAL GAS DIESEL OIL PKS (SUMATRA / BORNEO) PKS (JAVA) EFB (SUMATRA / BORNEO) RICE HUSKS COCOA SHELLS 135, IDR/mmBtu ( 9.00 USD/mmBtu) 8, IDR/l ( 0.55 USD/L) 750, IDR/ton ( USD/ton) 900, IDR/ton ( USD/ton) 225, IDR/ton ( USD/ton) 900, IDR/ton ( USD/ton) 1,400, IDR/ton ( USD/ton) 11,800 kcal/kg USD/ton steam 9,500 kcal/kg USD/ton steam 3,800 kcal/kg 8.65 USD/ton steam 3,800 kcal/kg USD/ton steam 1,600 kcal/kg 6.15 USD/ton steam 3,000 kcal/kg 3.30 USD/ton steam 3,800 kcal/kg USD/ton steam

32 ANNUAL FUEL COST (USD/YEAR) RULES OF THUMB IMPORTANCE OF EFFICIENCY! Annual Fuel Cost vs Boiler Efficiency 300, Calculated based on 8,000 hours/year operation with 60 USD/ton PKS at 3,800 kcal/kg 250, , , , ton/h 15 ton/h 20 ton/h 25 ton/h 50, % 83% 82% 81% 80% 79% 78% 77% 76% 75% BOILER EFFICIENCY (%)

33 RULES OF THUMB OPERATIONAL CLEANLINESS

34 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

35 CASE STUDY RICE INDUSTRY THE PROCESS

36 CASE STUDY RICE INDUSTRY ENERGY REQUIREMENTS BOILER TYPE WTB-V BOILER PARAMETERS Flow: 34 t/h Pressure: 40 bar(a) Temperature: 450 C CAPACITY 21 MW th 5.5 MW e parasitical load 550 kwe BOILER EFFICIENCY > 86% BOILER AVAILABILITY > hours/year FUEL CONSUMPTION Rice husks: 9,0 t/h t/month t/y Wood chips: 11,6 t/h t/month t/y Coal: 5,0 t/h t/month t/y

CASE STUDY RICE INDUSTRY MULTI FUEL COMBUSTION FOR BATULICIN PROJECT RICE HUSK WOOD CHIPS COAL Lower Heating

Minimum LHV Nominal LHV Maximal LHV 2 100 kcal/kg 2 350 kcal/kg 2 600 kcal/kg Lower Heating Value Minimum

tendency - Abrasive flue gasses - Corrosion on superheater Fuel challenges - High volatile matter, low fixed

37 CASE STUDY RICE INDUSTRY MULTI FUEL COMBUSTION FOR BATULICIN PROJECT RICE HUSK WOOD CHIPS COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg kcal/kg kcal/kg Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg kcal/kg kcal/kg Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg kcal/kg kcal/kg Fuel challenges - High fouling tendency - Abrasive flue gasses - Corrosion on superheater Fuel challenges - High volatile matter, low fixed carbon - Varying LHV and moisture content Fuel challenges - High fixed carbon, low volatile matter - High sulfur content

39 CASE STUDY RICE INDUSTRY HIGHLIGHTS : MULTI FUEL SOLUTION

40 RICE HUSKS 2011 NANCHANG, CHINA

41 RICE HUSKS, CORN COBS 2017 SOUTH COTABATO, PHILIPPINES

42 RICE HUSKS, WOOD CHIPS, CORN COBS 2009 AYUTTHAYA, THAILAND

43 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

44 CASE STUDY INSTANT COFFEE THE PROCESS

CASE STUDY INSTANT COFFEE FUEL CHALLENGES SPENT COFFEE GROUNDS Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 1 600 kcal/kg 2 150 kcal/kg 2 400

45 CASE STUDY INSTANT COFFEE FUEL CHALLENGES SPENT COFFEE GROUNDS Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg kcal/kg kcal/kg Fuel challenges - Very high moisture content (45% - 55%) - Very fine dimension - Acidic and corrosive - Sticky with tendency to bridge - Low air penetration

46 CASE STUDY INSTANT COFFEE SOLUTION BOILER TYPE JNO BOILER PARAMETERS Flow: 20 t/h Pressure: 25 bar(g) Temperature: Saturated BOILER EFFICIENCY > 85% 100% CSG NATURAL GAS FUEL COST 0 Rp/t 4,350 Rp/m³ FUEL / HOUR 7 t/h 1800 m³/h FUEL COST / HOUR 0 Rp 7,830,000 Rp/h FUEL COST / YEAR 0 Rp 62,640,000,000 Rp PAYBACK < 2 years - BOILER AVAILABILITY FUEL > hours/year 100% Spent Coffee Grounds Backup gas burners

47 CASE STUDY INSTANT COFFEE SOME HIGHLIGHTS

48 COFFEE SPENT GROUNDS, WOOD CHIPS 2013 GRACE-HOLLOGNE, BELGIUM

49 COFFEE SPENT GROUNDS 2013 JOURE, NETHERLANDS

50 COFFEE SPENT GROUNDS, COFFEE HUSKS, WOOD CHIPS 2016 DIEPPE, FRANCE

51 WHO IS VYNCKE? VYNCKE IN A NUTSHELL TECHNOLOGY RULES OF THUMB CASE STUDY RICE MILL, KALIMANTAN SELATAN CASE STUDY INSTANT COFFEE PLANT, JAVA CASE STUDY CPO REFINERY, SUMATRA

52 CASE STUDY CPO REFINERY THE PROCESS

53 CASE STUDY CPO REFINERY CASE DEFINITION STEAM DEMAND: INSTALLED BASE: t/h coal & PKS fired boilers REQUEST: - Reduce carbon footprint of the refinery - Reduce energy cost of the refinery - Replace low efficiency biomass boilers (< 55% on GCV) - Generate base load steam (75 t/h 35 bar(g)) with EFB - Flexibility to run on EFB & coal

54 CASE STUDY CPO REFINERY FUEL CHALLENGES PRESSED & SHREDDED EMPTY FRUIT BUNCHES COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg 55%mc kcal/kg 47%mc kcal/kg 40%mc Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg 40%mc kcal/kg 32%mc kcal/kg 28%mc Chemical composition - Density : kg/m³ - Ash melting T: 900 C - Ash: 7.5% - Cl: 0.4% - S: 0.15% Chemical - Density : kg/m³ - Ash melting T: 1300 C - Ash: % - Cl: 0.15% - S: 1%

LHV Maximal LHV 4 170 kcal/kg 40%mc 4 380 kcal/kg 32%mc 4 780 kcal/kg 28%mc Fuel challenges - Very high

55 CASE STUDY CPO REFINERY FUEL CHALLENGES PRESSED & SHREDDED EMPTY FRUIT BUNCHES COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg kcal/kg kcal/kg Lower Heating Value Minimum LHV Nominal LHV Maximal LHV kcal/kg 40%mc kcal/kg 32%mc kcal/kg 28%mc Fuel challenges - Very high moisture content (45% - 55%) - Abrasive - Fluffy and fibrous with tendency to bridge - Very low ash melting temperature

bar(g) @ 100% EFB 95 t/h 35 bar(g) @ 100% coal > 89% @ 100% EFB > 90% @ 100% coal > 8 000 hours/year 251.

56 CASE STUDY CPO REFINERY VYNCKE SOLUTION BIOMASS SOLUTION COAL FIRED CFBC BOILER BOILER TYPE WTB-V FUEL COST 16 USD/t 2 USD/GJ 45 USD/t 3 USD/GJ BOILER PARAMETERS BOILER EFFICIENCY (NCV) BOILER AVAILABILITY CO 2 REDUCTION 75 t/h % EFB 95 t/h % coal > 100% EFB > 100% coal > hours/year % EFB TURNKEY CAPEX 12,500,000 USD 9,000,000 USD IRR 24% 28% PAYBACK 4.2 years 3.7 years CO 2 REDUCTION t/y -

57 CASE STUDY CPO REFINERY VYNCKE SOLUTION

58 CASE STUDY SOME HIGHLIGHTS Slagging on furnace walls: Consequences of non water-cooled furnace walls Clinkering on combustion grate: Consequences of non watercooled combustion grate

59 Temperature C Temperature C CASE STUDY SOME HIGHLIGHTS Insulation 100mm Calcium silicate board 100mm water tube 60mm Insulating brick lining 125mm Dense refractory lining 70mm Dense refractory lining 150mm ,100 C 1,200 C ,100 C 1,200 C 1000 Ash melting point of EFB = 900 C Thickness (in mm) Thickness (in mm)

60 PALM FIBERS & PALM KERNEL SHELLS 2004 SUNGAI DINGIN

61 EMPTY FRUIT BUNCHES 2013 LAHAD DATU

62 EMPTY FRUIT BUNCHES 2013 TELUK INTAN

63 ANY QUESTIONS? RENEWABLE ENERGY SOLUTIONS SINCE

Energy Efficiency with IKN Pendulum Cooler

Energy Efficiency with IKN Pendulum Cooler BEE, WORKSHOP on 08.11.2016 R. Madhusudan (Country Head, IKN India) Savings of power consumption = 1.5 kwh/t Savings in power of India if all clinker is cooled