part 1: overview of cogeneration and its status in asia - Fire

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Cogeneration in Asia today 63 Every ton of paddy processed generates around 250 kg of husk which, when used as fuel, is capable of producing 100 kWh of electricity on an average. The milling power needed for a ton of paddy ranges from 20 kWh for white rice production to 60 kWh for parboiling and mechanically dried white rice. Assuming that 2.7 kg of husk are necessary to produce 1 kWh, theoretically over 13,000 GWh/year of electricity could be generated. In practice, however, much less may be expected from the rice-milling sector as financial analyses show power generation to be feasible only for plants having a capacity above 5 tons/hour. As shown in Table 1.6, rice-milling capacities of many ASEAN factories are far too small to be financially attractive for cogeneration applications. Country Rice mills Paddy (10 6 tons) Indonesia Malaysia Philippines Thailand Viet Nam >78,000 380 >13,000 17,000 >100,000 1.8.2 Sugar industry Table 1.6 Status of rice industry in ASEAN 49.7 2.2 10.5 33.8 24.9 Rice husk (10 6 tons) 10.94 47.0 2.32 7.45 5.49 Generation potential (GWh/year) 5,472 237 1,160 3,725 2,746 Milling capacity (>5 tph) 0 62 71 78 55 Generation capacity (MW) 0 28 68 61 66 In most sugar mills, bagasse generated as residue is utilized for heat and power generation. There are over 150 sugar mills in the ASEAN, producing close to 35 million tons of bagasse annually. A little less than one-third of the raw sugar cane is turned into bagasse. Processing one ton of sugarcane will generate an average of 300 kg of bagasse. Assuming that bagasse is consumed efficiently, 3 kg of bagasse is necessary to produce a kWh of electricity. Based on this, the technical potential for power generation from bagasse in ASEAN can be estimated at 11,600 GWh/year (see Table 1.7). However, the existing equipment in most facilities is old and inefficient, often resulting in the generation of low-pressure steam. There is a need for adopting boilers of higher capacities and pressures greater than 40 bar. Country Sugar mills Indonesia Malaysia Philippines Thailand Viet Nam Table 1.7 Status of sugar industry in ASEAN 67 N.A. 36 46 16 1.8.3 Palm oil industry Sugarcane (10 6 tons) 29.05 N.A. 18.50 57.97 11.29 Bagasse (10 6 tons) 8.72 N.A. 5.55 17.39 3.39 Generation potential (GWh/year) 2,906 N.A. 1,777 5,797 1,129 Generating capacity (MW) 792 N.A. 758 1,871 54 In a palm oil industry, as much as 70 per cent of the fresh fruit bunches (FFB) are turned into wastes such as empty bunches (23 per cent), fibres and shells (19 per cent), while between 600 and 700 kg of liquid effluent are produced per ton of FFB. Though many palm oil mills generate combined heat and power from fibres and shells, the use of palm oil residues could still be optimized. Fibres and shells generated by a ton of FFB can produce approximately 45 kWh; empty bunches could contribute to another 35 kWh of electricity generation.
64 Part II: Cogeneration experiences in Asia and elsewhere More than 40 million tons of fresh fruit bunches are processed annually (of which, almost 75 per cent are in Malaysia alone) by about 430 mills in ASEAN. Thus the technical potential for power generation from solid residues from ASEAN palm oil industry amounts to over 3,200 GWh/year and around 2,470 MW of total generating capacity. 1.8.4 Wood industry The wood industry - including sawmills, plywood factories and furniture industries - converts about half of the raw wood into residue during the production process. The wood waste generated in the plant is capable of generating as much as 150 kWh of electricity. But the majority of sawmills in ASEAN (mostly located in Indonesia and Malaysia) are either connected to the national grid or use diesel generators to meet their electricity demand. The plywood industry requires large amount of power and heat. The wood waste can be effectively utilized to cogenerate heat and power to satisfy all the energy demand of the plant. Financial analyses carried out on some specific projects show that the pay-back period on investment would be around 3 to 4 years, thus making the wood cogeneration market most lucrative. The owners of integrated factories, combining sawmill, plywood and furniture making, can benefit a lot through better utilization of the cogeneration plant capacity. The technical potential for power generation from over 19 million tons of residues in ASEAN wood industry is assessed to be over 4,800 GWh/year and around 920 MW of total generating capacity can be expected. 1.8.5 Full-scale demonstration projects Many biomass energy technologies are technically sound and economically viable, and yet have not yet been implemented due to a number of reasons, the most important among them are the lack of awareness and unavailability of suitable technologies. The EC-ASEAN COGEN Programme attempts to establish references for such technologies and to accelerate the implementation of proven technologies in ASEAN by launching full-scale demonstration projects (FSDP). Financial and technical assistance is extended to implement proven technologies on full-scale basis in the hope that replication of such projects will reduce fossil fuel dependence and will contribute to the protection of the environment. To date, about 15 full-scale demonstration projects (FSDPs) have been commissioned under this Programme. The salient features of some of these projects are highlighted below. Wood waste-based cogeneration This is a factory located in Sarawak, Malaysia. The project consists of a 1.65 MW wood waste-fired power plant that includes a boiler with a capacity to produce 30 tons/hour (tph) of steam at 21 bar. Steam is supplied to a fully condensing turbine to produce 1,650 kW of power. About 10 tph of process steam is required at 7 bar to be used for kiln drying of wood. The total cost of the project is a little less than US$ 2 million and the payback period is calculated as 3.1 years. Cogeneration in a rice mill This is a factory located in Nakorn Ratchasima, Thailand. The project consists of a rice huskfired 2.5 MW power plant that includes a boiler producing 17 tph of steam at 35 bar. This steam is supplied to a condensing turbine to generate 2.5 MW of power. Flue gas from the boiler is used for paddy drying. The total cost of the project is around US$ 3.87 million and the payback period is estimated as 3.6 years.
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PART 1: OVERVIEW OF COGENERATION AN
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Summary of country study - Viet Nam
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