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

BIOMASS ENERGY SYSTEMS FOR F&B INDUSTRY: CASE STUDIES IN AN INDONESIAN PERSPECTIVE Kevin Vandewalle 27 Sep 2018 WWW.VYNCKE.COM

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

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

VYNCKE IN A NUTSHELL FAMILY OWNED 4 th GENERATION COMPANY

VYNCKE IN A NUTSHELL HISTORY

VYNCKE IN A NUTSHELL BIOMASS TO CLEAN ENERGY 7 @ Indonesia

VYNCKE IN A NUTSHELL ENERGY MEDIA STEAM (5 80 TPH) HOT WATER (0.5 30 MW t ) HOT GAS (1 100 MW t ) THERMAL OIL (1 30 MW t ) ELECTRICITY (0.5 15 MW e )

VYNCKE IN A NUTSHELL SOLUTIONS

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

MARKETS WOOD

MARKETS WOOD

MARKETS FOOD & AGRI

MARKETS FOOD & AGRI

MARKETS RENEWABLES

MARKETS RENEWABLES

VYNCKE IN A NUTSHELL ENERGIZING THE INDUSTRY

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

TECHNOLOGY BIOMASS : BALANCING THROUGH EXPERIENCE

TECHNOLOGY BIOMASS A FUEL COMPARISON

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

TECHNOLOGY THE ART OF MAKING FIRE WHAT?

TECHNOLOGY THE ART OF MAKING FIRE A COMPARISON

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

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 %

TECHNOLOGY BOILER SELECTION FOR THE F&B INDUSTRY

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

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

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 1,000 0 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% % of operating time

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

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 135,000.00 IDR/mmBtu ( 9.00 USD/mmBtu) 8,000.00 IDR/l ( 0.55 USD/L) 750,000.00 IDR/ton ( 50.00 USD/ton) 900,000.00 IDR/ton ( 60.00 USD/ton) 225,000.00 IDR/ton ( 15.00 USD/ton) 900,000.00 IDR/ton ( 15.00 USD/ton) 1,400,000.00 IDR/ton ( 95.00 USD/ton) 11,800 kcal/kg 23.47 USD/ton steam 9,500 kcal/kg 38.07 USD/ton steam 3,800 kcal/kg 8.65 USD/ton steam 3,800 kcal/kg 10.38 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 16.44 USD/ton steam

ANNUAL FUEL COST (USD/YEAR) RULES OF THUMB IMPORTANCE OF EFFICIENCY! Annual Fuel Cost vs Boiler Efficiency 300,000.00 Calculated based on 8,000 hours/year operation with 60 USD/ton PKS at 3,800 kcal/kg 250,000.00 200,000.00 150,000.00 100,000.00 10 ton/h 15 ton/h 20 ton/h 25 ton/h 50,000.00-84% 83% 82% 81% 80% 79% 78% 77% 76% 75% BOILER EFFICIENCY (%)

RULES OF THUMB OPERATIONAL CLEANLINESS

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

CASE STUDY RICE INDUSTRY THE PROCESS

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 > 8 000 hours/year FUEL CONSUMPTION Rice husks: 9,0 t/h 6 480 t/month 77 760 t/y Wood chips: 11,6 t/h 8 350 t/month 100 200 t/y Coal: 5,0 t/h 3 600 t/month 43 200 t/y

CASE STUDY RICE INDUSTRY MULTI FUEL COMBUSTION FOR BATULICIN PROJECT RICE HUSK WOOD CHIPS COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 2 880 kcal/kg 2 955 kcal/kg 3 360 kcal/kg Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 2 100 kcal/kg 2 350 kcal/kg 2 600 kcal/kg Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 4 780 kcal/kg 5 380 kcal/kg 6 000 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

CASE STUDY RICE INDUSTRY HIGHLIGHTS : MULTI FUEL SOLUTION

RICE HUSKS 2011 NANCHANG, CHINA

RICE HUSKS, CORN COBS 2017 SOUTH COTABATO, PHILIPPINES

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

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

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 kcal/kg Fuel challenges - Very high moisture content (45% - 55%) - Very fine dimension - Acidic and corrosive - Sticky with tendency to bridge - Low air penetration

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 > 8 000 hours/year 100% Spent Coffee Grounds Backup gas burners

CASE STUDY INSTANT COFFEE SOME HIGHLIGHTS

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

COFFEE SPENT GROUNDS 2013 JOURE, NETHERLANDS

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

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

CASE STUDY CPO REFINERY THE PROCESS

CASE STUDY CPO REFINERY CASE DEFINITION STEAM DEMAND: INSTALLED BASE: 120 150 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

CASE STUDY CPO REFINERY FUEL CHALLENGES PRESSED & SHREDDED EMPTY FRUIT BUNCHES COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 1 580 kcal/kg 55%mc 1 960 kcal/kg 47%mc 2 300 kcal/kg 40%mc Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 4 170 kcal/kg 40%mc 4 380 kcal/kg 32%mc 4 780 kcal/kg 28%mc Chemical composition - Density : 100 200 kg/m³ - Ash melting T: 900 C - Ash: 7.5% - Cl: 0.4% - S: 0.15% Chemical - Density : 700 800 kg/m³ - Ash melting T: 1300 C - Ash: 12.5-20% - Cl: 0.15% - S: 1%

CASE STUDY CPO REFINERY FUEL CHALLENGES PRESSED & SHREDDED EMPTY FRUIT BUNCHES COAL Lower Heating Value Minimum LHV Nominal LHV Maximal LHV 1 580 kcal/kg 1 960 kcal/kg 2 300 kcal/kg Lower Heating Value Minimum LHV Nominal 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 moisture content (45% - 55%) - Abrasive - Fluffy and fibrous with tendency to bridge - Very low ash melting temperature

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 35 bar(g) @ 100% EFB 95 t/h 35 bar(g) @ 100% coal > 89% @ 100% EFB > 90% @ 100% coal > 8 000 hours/year 251.680 t/year @ 100% EFB TURNKEY CAPEX 12,500,000 USD 9,000,000 USD IRR 24% 28% PAYBACK 4.2 years 3.7 years CO 2 REDUCTION 251.680 t/y -

CASE STUDY CPO REFINERY VYNCKE SOLUTION

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

100 200 300 400 500 600 100 200 300 400 500 600 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 1200 1,100 C 1,200 C 1200 1,100 C 1,200 C 1000 Ash melting point of EFB = 900 C 1000 800 800 600 600 400 400 200 200 Thickness (in mm) Thickness (in mm)

PALM FIBERS & PALM KERNEL SHELLS 2004 SUNGAI DINGIN

EMPTY FRUIT BUNCHES 2013 LAHAD DATU

EMPTY FRUIT BUNCHES 2013 TELUK INTAN

ANY QUESTIONS? RENEWABLE ENERGY SOLUTIONS SINCE 1912 WWW.VYNCKE.COM