Biomass residue from palm oil industries are attractive renewable energy fuel in Southeast Asia. The abundance of these biomass resources is increasing with the fast development of palm oil industries in Malaysia, Indonesia and Thailand. In the Palm Oil value chain there is an overall surplus of by-products and the utilisation rate of these by-products is low.
Palm kernel shells (or PKS) are the shell fractions left after the nut has been removed after crushing in the Palm Oil mill. Kernel shells are a fibrous material and can be easily handled in bulk directly from the product line to the end use. Large and small shell fractions are mixed with dust-like fractions and small fibres.
Moisture content in kernel shells is low compared to other biomass residues with different sources suggesting values between 11% and 13%. Palm kernel shells contain residues of Palm Oil, which accounts for its slightly higher heating value than average lignocellulosic biomass. Compared to other residues from the industry, it is a good quality biomass fuel with uniform size distribution, easy handling, easy crushing, and limited biological activity due to low moisture content.
Press fibre and shell generated by the palm oil mills are traditionally used as solid fuels for steam boilers. The steam generated is used to run turbines for electricity production. These two solid fuels alone are able to generate more than enough energy to meet the energy demands of a palm oil mill. Most palm oil mills in the region are self-sufficient in terms of energy by making use of kernel shells and mesocarp fibers in cogeneration. The demand for palm kernel shells has increased considerably in Malaysia, Indonesia and Thailand resulting in price close to that of coal. Nowadays, cement industries are using palm kernel shells to replace coal mainly because of CDM benefits.
The problems associated with the burning of these solid fuels are the emissions of dark smoke and the carry-over of partially carbonized fibrous particulates due to incomplete combustion of the fuels can be tackled by commercially-proven technologies in the form of high-pressure boilers. Dual-fired boilers capable of burning either diesel oil or natural gas are the most suitable for burning palm Oil waste since they could also facilitate the use of POME-derived biogas as a supplementary fuel. However, there is a great scope for introduction of high-efficiency CHP systems in the industry which will result in substantial supply of excess power to the public grid.
Combined heat and power systems in the biomass industry means the simultaneous generation of multiple forms of useful energy (usually mechanical and thermal) from biomass resources in a single, integrated system. In a conventional electricity generation systems, about 35% of the energy potential contained in the fuel is converted on average into electricity, whilst the rest is lost as waste heat. CHP systems use both electricity and heat and therefore can achieve an efficiency of up to 90%.
CHP technologies are well suited for sustainable development projects because they are socio-economically attractive and technologically mature and reliable. In developing countries, cogeneration can easily be integrated in many industries, especially agriculture and food processing, taking advantage of the biomass residues of the production process. This has the dual benefits of lowering fuel costs and solving waste disposal issues.
CHP systems consist of a number of individual components—prime mover (heat engine), generator, heat recovery, and electrical interconnection—configured into an integrated whole. Prime movers for CHP units include reciprocating engines, combustion or gas turbines, steam turbines, microturbines, and fuel cells. A typical CHP system provides:
Distributed generation of electrical and/or mechanical power.
Waste-heat recovery for heating, cooling, or process applications.
Seamless system integration for a variety of technologies, thermal applications, and fuel types.
The success of any biomass-fuelled CHP project is heavily dependent on the availability of a suitable biomass feedstock freely available in urban and rural areas.
Urban wood waste
Municipal solid wastes
Food processing residues
Reciprocating or internal combustion engines (ICEs) are among the most widely used prime movers to power small electricity generators. Advantages include large variations in the size range available, fast start-up, good efficiencies under partial load efficiency, reliability, and long life.
Steam turbines are the most commonly employed prime movers for large power outputs. Steam at lower pressure is extracted from the steam turbine and used directly or is converted to other forms of thermal energy. System efficiencies can vary between 15 and 35% depending on the steam parameters.
Co-firing of biomass with coal and other fossil fuels can provide a short-term, low-risk, low-cost option for producing renewable energy while simultaneously reducing the use of fossil fuels. Biomass can typically provide between 3 and 15 percent of the input energy into the power plant. Most forms of biomass are suitable for co-firing.
Steam engines are also proven technology but suited mainly for constant speed operation in industrial environments. Steam engines are available in different sizes ranging from a few kW to more than 1 MWe.
A gas turbine system requires landfill gas, biogas, or a biomass gasifier to produce the gas for the turbine. This biogas must be carefully filtered of particulate matter to avoid damaging the blades of the gas turbine.
Stirling engines utilize any source of heat provided that it is of sufficiently high temperature. A wide variety of heat sources can be used but the Stirling engine is particularly well-suited to biomass fuels. Stirling engines are available in the 0.5 to 150 kWe range and a number of companies are working on its further development.
A micro-turbine recovers part of the exhaust heat for preheating the combustion air and hence increases overall efficiency to around 20-30%. Several competing manufacturers are developing units in the 25-250kWe range. Advantages of micro-turbines include compact and light weight design, a fairly wide size range due to modularity, and low noise levels.
Fuel cells are electrochemical devices in which hydrogen-rich fuel produces heat and power. Hydrogen can be produced from a wide range of renewable and non-renewable sources. A future high temperature fuel cell burning biomass might be able to achieve greater than 50% efficiency.
Thailand’s annual energy consumption has risen sharply during the past decade and will continue its upward trend in the years to come. While energy demand has risen sharply, domestic sources of supply are limited, thus forcing a significant reliance on imports.
To face this increasing demand, Thailand needs to produce more energy from its own renewable resources, particularly biomass wastes derived from agro-industry, such as bagasse, rice husk, wood chips, livestock and municipal wastes.
In 2005, total installed power capacity in Thailand was 26,430 MW. Renewable energy accounted for about 2 percent of the total installed capacity. In 2007, Thailand had about 777 MW of electricity from renewable energy that was sold to the grid.
Biomass Potential in Thailand
Several studies have projected that biomass wastes can cover up to 15 % of the energy demand in Thailand. These estimations are primarily made from biomass waste from the extraction part of agricultural activities, and for large scale agricultural processing of crops etc. – as for instance saw and palm oil mills – and do not include biomass wastes from SMEs in Thailand. Thus, the energy potential of biomass waste can be much larger if these resources are included. The major biomass resources in Thailand include the following:
Wood residues from wood and furniture industries (bark, sawdust, etc.)
Biomass for ethanol production (cassava, sugar cane, etc.)
Biomass for biodiesel production (palm oil, jatropha oil, etc.)
Industrial wastewater from agro-industry
Municipal solid wastes and sewage
Thailand’s vast biomass potential has been partially exploited through the use of traditional as well as more advanced conversion technologies for biogas, power generation, and biofuels. Rice, sugar, palm oil, and wood-related industries are the major potential biomass energy sources in Thailand. The country has a fairly large biomass resource base of about 60 million tons generated each year that could be utilized for energy purposes, such as rice, sugarcane, rubber sheets, palm oil and cassava.
Biomass has been a primary source of energy for many years, used for domestic heating and industrial cogeneration. For example, paddy husks are burned to produce steam for turbine operation in rice mills; bagasse and palm residues are used to produce steam and electricity for on-site manufacturing process; and rubber wood chips are burned to produce hot air for rubber wood seasoning.
In addition to biomass residues, wastewater containing organic matters from livestock farms and industries has increasingly been used as a potential source of biomass energy. Thailand’s primary biogas sources are pig farms and residues from food processing. The production potential of biogas from industrial wastewater from palm oil industries, tapioca starch industries, food processing industries, and slaughter industries is also significant. The energy-recovery and environmental benefits that the KWTE waste to energy project has already delivered is attracting keen interest from a wide range of food processing industries around the world.
The cultivation of rice results in two major types of biomass wastes – Straw and Husk –having attractive potential in terms of biomass energy. Although the technology for rice husk utilization is well-proven in industrialized countries of Europe and North America, such technologies are yet to be introduced in the developing world on commercial scale.
The importance of Rice Husk and Rice Straw as an attractive source of energy can be gauged from the following statistics:
1 ton of Rice paddy produces 290 kg Rice Straw
290 kg Rice Straw can produce 100 kWh of power
Calorific value = 2400 kcal/kg
1 ton of Rice paddy produces 220 kg Rice Husk
1 ton Rice Husk is equivalent to 410- 570 kWh electricity
Calorific value = 3000 kcal/kg
Moisture content = 5 – 12%
Rice husk is the most prolific agricultural residue in rice producing countries around the world. It is one of the major by-products from the rice milling process and constitutes about 20% of paddy by weight. Rice husk, which consists mainly of lingo-cellulose and silica, is not utilized to any significant extent and has great potential as an energy source.
Rice husk can be used for power generation through either the steam or gasification route. For small scale power generation, the gasification route has attracted more attention as a small steam power plant is very inefficient and is very difficult to maintain due to the presence of a boiler. In addition for rice mills with diesel engines, the gas produced from rice husk can be used in the existing engine in a dual fuel operation.
The benefits of using rice husk technology are numerous. Primarily, it provides electricity and serves as a way to dispose of agricultural waste. In addition, steam, a byproduct of power generation, can be used for paddy drying applications, thereby increasing local incomes and reducing the need to import fossil fuels. Rice husk ash, the byproduct of rice husk power plants, can be used in the cement and steel industries further decreasing the need to import these materials.
Rice straw can either be used alone or mixed with other biomass materials in direct combustion. In this technology, combustion boilers are used in combination with steam turbines to produce electricity and heat. The energy content of rice straw is around 14 MJ per kg at 10 percent moisture content. The by-products are fly ash and bottom ash, which have an economic value and could be used in cement and/or brick manufacturing, construction of roads and embankments, etc.
Straw fuels have proved to be extremely difficult to burn in most combustion furnaces, especially those designed for power generation. The primary issue concerning the use of rice straw and other herbaceous biomass for power generation is fouling, slagging, and corrosion of the boiler due to alkaline and chlorine components in the ash. Europe, and in particular, Denmark, currently has the greatest experience with straw fired power and CHP plants.
The valuable component of biogas is methane (CH4) which typically makes up 60%, with the balance being carbon dioxide (CO2) and small percentages of other gases. The proportion of methane depends on the feedstock and the efficiency of the process, with the range for methane content being 40% to 70%. Biogas is saturated and contains H2S, and the simplest use is in a boiler to produce hot water or steam.
DaishThe gas can also be upgraded and used in gas supply networks. The use of biogas in solid oxide fuel cells is also being researched.
Biogas can be combusted directly to produce heat. In this case, there is no need to scrub the hydrogen sulphide in the biogas. Usually the process utilize dual-fuel burner and the conversion efficiency is 80 to 90%. The main components of the system are anaerobic digester, biogas holder, pressure switch, booster fan, solenoid valve, dual fuel burner and combustion air blower.
The most common method for utilization of biogas in developing countries is for cooking and lighting. Conventional gas burners and gas lamps can easily be adjusted to biogas by changing the air to gas ratio. In more industrialized countries boilers are present only in a small number of plants where biogas is used as fuel only without additional CHP. In a number of industrial applications biogas is used for steam production.
Burning biogas in a boiler is an established and reliable technology. Low demands are set on the biogas quality for this application. Pressure usually has to be around 8 to 25 mbar. Furthermore it is recommended to reduce the level of hydrogen sulphide to below 1 000 ppm, this allows to maintain the dew point around 150 °C.
Biogas is the ideal fuel for generation of electric power or combined heat and power. A number of different technologies are available and applied. The most common technology for power generation is internal combustion. Engines are available in sizes from a few kilowatts up to several megawatts. Gas engines can either be SI-engines (spark ignition) or dual fuel engines. Dual fuel engines with injection of diesel (10% and up) or sometimes plant oil are very popular in smaller scales because they have good electric efficiencies up to guaranteed 43%.
The biogas pressure is turbo-charged and after-cooled and has a high compression ratio in the gas engines. The cooling tower provides cooling water for the gas engines. The main component of the system required for utilizing the technology are anaerobic digester, moisture remover, flame arrester, waste gas burner, scrubber, compressor, storage, receiver, regulator, pressure switch and switch board.
Gas turbines are an established technology in sizes above 500 kW. In recent years also small scale engines, so called micro-turbines in the range of 25 to 100kW have been successfully introduced in biogas applications. They have efficiencies comparable to small SI-engines with low emissions and allow recovery of low pressure steam which is interesting for industrial applications. Micro turbines are small, high-speed, integrated power plants that include a turbine, compressor, generator and power electronics to produce power.
The benefit of the anaerobic treatment will depend on the improvement of the process regarding a higher biogas yield per m3 of biomass and an increase in the degree of degradation. Furthermore, the benefit of the process can be multiplied by the conversion of the effluent from the process into a valuable product.
In order to improve the economical benefit of biogas production, the future trend will go to integrated concepts of different conversion processes, where biogas production will still be a significant part. In a so-called biorefinery concept, close to 100% of the biomass is converted into energy or valuable by-products, making the whole concept more economically profitable and increasing the value in terms of sustainability.
One example of such biorefinery concept is the Danish Bioethanol Concept that combines the production of bioethanol from lignocellulosic biomass with biogas production of the residue stream. Another example is the combination of biogas production from manure with manure separation into a liquid and a solid fraction for separation of nutrients. One of the most promising concepts is the treatment of the liquid fraction on the farm-site in a UASB reactor while the solid fraction is transported to the centralized biogas plant where wet-oxidation can be implemented to increase the biogas yield of the fiber fraction. Integration of the wet oxidation pre-treatment of the solid fraction leads to a high degradation efficiency of the lignocellulosic solid fraction.
Vietnam is one of the few countries having a low level of energy consumption in the developing world with an estimated amount of 210 kg of oil equivalent per capita/year. Over half of the Vietnamese population does not have access to electricity. Vietnam is facing the difficult challenge of maintaining this growth in a sustainable manner, with no or minimal adverse impacts on society and the environment.
Being an agricultural country, Vietnam has very good biomass energy potential. Agricultural wastes are most abundant in the Mekong Delta region with approximately 50% of the amount of the whole country and Red River Delta with 15%. Major biomass resources includes rice husk from paddy milling stations, bagasse from sugar factories, coffee husk from coffee processing plants in the Central Highlands and wood chip from wood processing industries. Vietnam has set a target of having a combined capacity of 500 MW of biomass power by 2020, which is raised to 2,000 MW in 2030.
Rice husk and bagasse are the biomass resources with the greatest economic potential, estimated at 50 MW and 150 MW respectively. Biomass fuels sources that can also be developed include forest wood, rubber wood, logging residues, saw mill residues, sugar cane residues, bagasse, coffee husk and coconut residues.
Currently biomass is generally treated as a non-commercial energy source, and collected and used locally. Nearly 40 bagasse-based biomass power plants have been developed with a total designed capacity of 150 MW but they are still unable to connect with the national grid due to current low power prices. Five cogeneration systems selling extra electricity to national grid at average price of 4UScents/kWh.
Biogas energy potential is approximately 10 billion m3/year, which can be collected from landfills, animal excrements, agricultural residues, industrial wastewater etc. The biogas potential in the country is large due to livestock population of more than 30 million, mostly pigs, cattle, and water buffalo. Although most livestock dung already is used in feeding fish and fertilizing fields and gardens, there is potential for higher-value utilization through biogas production.
It is estimated that more than 25,000 household biogas digesters with 1 to 50 m3, have been installed in rural areas. The Dutch-funded Biogas Program operated by SNV Vietnam constructed some 18,000 biogas facilities in 12 provinces between 2003 and 2005, with a second phase (2007-2010) target of 150,000 biogas tanks in both rural and semi-urban settings.
Municipal solid waste is also a good biomass resource as the amount of solid waste generated in Vietnam has been increasing steadily over the last few decades. In 1996, the average amount of waste produced per year was 5.9 million tons per annum which rose to 28 million tons per in 2008 and expected to reach 44 million tons per year by 2015.
Biomass fuels are typically used most efficiently and beneficially when generating both power and heat through biomass cogeneration systems (also known as combined heat and power or CHP system). Biomass conversion technologies transform a variety of wastes into heat, electricity and biofuels by employing a host of strategies. Conversion routes are generally thermochemical or biochemical, but may also include chemical and physical.
The simplest way is to burn the biomass in a furnace, exploiting the heat generated to produce steam in a boiler, which is then used to drive a steam turbine. Advanced biomass conversion technologies include biomass integrated gasification combined cycle (BIGCC) systems, cofiring (with coal or gas), pyrolysis and second generation biofuels.
Biomass Cogeneration Systems
A typical biomass cogeneration (or biomass cogen) system provides:
Distributed generation of electrical and/or mechanical power.
Waste-heat recovery for heating, cooling, or process applications.
Seamless system integration for a variety of technologies, thermal applications, and fuel types into existing building infrastructure.
Biomass cogeneration systems consist of a number of individual components—prime mover (heat engine), generator, heat recovery, and electrical interconnection—configured into an integrated whole. The type of equipment that drives the overall system (i.e., the prime mover) typically identifies the CHP unit.
Prime movers for biomass cogeneration units include reciprocating engines, combustion or gas turbines, steam turbines, microturbines, and fuel cells. These prime movers are capable of burning a variety of fuels, including natural gas, coal, oil, and alternative fuels to produce shaft power or mechanical energy.
A biomass-fueled cogeneration facility is an integrated power system comprised of three major components:
Biomass receiving and feedstock preparation.
Energy conversion – Conversion of the biomass into steam for direct combustion systems or into biogas for the gasification systems.
Power and heat production – Conversion of the steam or syngas or biogas into electric power and process steam or hot water
Feedstock for Biomass Cogeneration Plants
The lowest cost forms of biomass for cogeneration plants are residues. Residues are the organic byproducts of food, fiber, and forest production, such as sawdust, rice husks, wheat straw, corn stalks, and sugarcane bagasse. Forest residues and wood wastes represent a large potential resource for energy production and include forest residues, forest thinnings, and primary mill residues.
Energy crops are perennial grasses and trees grown through traditional agricultural practices that are produced primarily to be used as feedstocks for energy generation, e.g. hybrid poplars, hybrid willows, and switchgrass. Animal manure can be digested anaerobically to produce biogas in large agricultural farms and dairies.
To turn a biomass resource into productive heat and/or electricity requires a number of steps and considerations, most notably evaluating the availability of suitable biomass resources; determining the economics of collection, storage, and transportation; and evaluating available technology options for converting biomass into useful heat or electricity.
There is immense potential of biomass energy in Southeast Asia due to plentiful supply of diverse forms of wastes such as agricultural residues, agro-industrial wastes, woody biomass, animal wastes, municipal solid waste, etc. Southeast Asia is a big producer of wood and agricultural products which, when processed in industries, produces large amounts of biomass residues.
The rapid economic growth and industrialization in Southeast Asian region is characterized by a significant gap between energy supply and demand. The energy demand in the region is expected to grow rapidly in the coming years which will have a profound impact on the global energy market. In addition, the region has many locations with high population density, which makes public health vulnerable to the pollution caused by fossil fuels.
Another important rationale for transition from fossil-fuel-based energy systems to renewable ones arises out of observed and projected impacts of climate change. Due to the rising share of greenhouse gas emissions from Asia, it is imperative on all Asian countries to promote sustainable energy to significantly reduce GHGs emissions and foster sustainable energy trends. Rising proportion of greenhouse gas emissions is causing large-scale ecological degradation, particularly in coastal and forest ecosystems, which may further deteriorate environmental sustainability in the region.
The reliance on conventional energy sources can be substantially reduced as the Southeast Asian region is one of the leading producers of biomass resources in the world. Southeast Asia, with its abundant biomass resources, holds a strategic position in the global biomass energy atlas.
Palm kernel shells is an abundant biomass resource in Southeast Asia
According to conservative estimates, the amount of biomass residues generated from sugar, rice and palm oil mills is more than 200-230 million tons per year which corresponds to cogeneration potential of 16-19 GW. Woody biomass is a good energy resource due to presence of large number of forests and wood processing industries in the region.
The prospects of biogas power generation are also high in the region due to the presence of well-established food processing, agricultural and dairy industries. Another important biomass resource is contributed by municipal solid wastes in heavily populated urban areas.
In addition, there are increasing efforts from the public and private sectors to develop biomass energy systems for efficient biofuel production, e.g. biodiesel and bioethanol. The rapid economic growth and industrialization in Southeast Asia has accelerated the drive to implement the latest biomass energy technologies in order to tap the unharnessed potential of biomass resources, thereby making a significant contribution to the regional energy mix.
Southeast Asia, with its abundant bioenergy resources, holds a strategic position in the global biomass energy atlas. There is immense biomass energy potential in Southeast Asian countries due to plentiful supply of diverse forms of biomass wastes, such as agricultural residues, woody biomass, animal wastes, municipal solid waste, etc. The rapid economic growth and industrialization in the region has accelerated the drive to implement the latest waste-to-energy technologies to tap the unharnessed potential of biomass resources.
Southeast Asia is a big producer of agricultural and wood products which, when processed in industries, produces large amounts of biomass residues. According to conservative estimates, the amount of biomass residues generated from sugar, rice and palm oil mills is more than 200-230 million tons per year which corresponds to cogeneration potential of 16-19 GW.
Rice mills in the region produce 38 million tonnes of rice husk as solid residue which is a good fuel for producing heat and power. Sugar industry is an integral part of the industrial scenario in Southeast Asia accounting for 7% of sugar production worldwide. Sugar mills in Thailand, Indonesia, Philippines and Vietnam generate 34 million tonnes of bagasse every year. Malaysia, Indonesia and Thailand account for 90% of global palm oil production leading to the generation of 27 million tonnes of waste per annum in the form of empty fruit bunches (EFBs), fibers and shells, as well as liquid effluent.
Woody biomass is a good energy resource due to presence of large number of forests in Southeast Asia. Apart from natural forests, non-industrial plantations of different types (e.g. coconut, rubber and oil palm plantations, fruit orchards, and trees in homesteads and gardens) have gained recognition as important sources of biomass. In addition, the presence of a large number of wood processing industries also generates significant quantity of wood wastes. The annual production of wood wastes in the region is estimated to be more than 30 million m3.
The prospects of biogas power generation are also high in the region, thanks to presence of well-established food-processing and dairy industries. Another important biomass resource is contributed by municipal solid wastes in heavily populated urban areas. In addition, there are increasing efforts both commercially and promoted by governments to develop biomass energy systems for efficient biofuel production, e.g. bio-diesel from palm oil.
Biomass resources, particularly residues from forests, wood processing, agricultural crops and agro-processing, are under-utilised in Southeast Asian countries. There is an urgent need to utilize biomass wastes for commercial electricity and heat production to cater to the needs of the industries as well as urban and rural communities.
Southeast Asian countries are yet to make optimum use of the additional power generation potential from biomass waste resources which could help them to partially overcome the long-term problem of energy supply. Technologies for biomass utilization which are at present widely used in Southeast counties need to be improved towards best practice by making use of the latest trends in the biomass energy sector.
Sugarcane trash (or cane trash) is an excellent biomass resource in sugar-producing countries worldwide. The amount of cane trash produced depends on the plant variety, age of the crop at harvest and soil and weather conditions. Typically it represents about 15% of the total above ground biomass at harvest which is equivalent to about 10-15 tons per hectare of dry matter. During the harvesting operation around 70-80% of the cane trash is left in the field with 20-30% taken to the mill together with the sugarcane stalks as extraneous matter.
Cane trash’s calorific value is similar to that of bagasse but has an advantage of having lower moisture content, and hence dries more quickly. Nowadays only a small quantity of this biomass is used as fuel, mixed with bagasse or by itself, at the sugar mill. The rest is burned in the vicinity of the dry cleaning installation, creating a pollution problem in sugar-producing nations.
Cane trash and bagasse are produced during the harvesting and milling process of sugarcane which normally lasts between 6 to 7 months. Cane trash can potentially be converted into heat and electrical energy. However, most of the trash is burned in the field due to its bulky nature and high cost incurred in collection and transportation.
Cane trash could be used as an off-season fuel for year-round power generation at sugar mills. There is also a high demand for biomass as a boiler fuel during the sugar-milling season. Sugarcane trash can also converted in biomass pellets and used in dedicated biomass power stations or co-fired with coal in power plants and cement kilns.
Burning of cane trash creates pollution in sugar-producing countries
Currently, a significant percentage of energy used for boilers in sugarcane processing is provided by imported bunker oil. Overall, the economic, environmental, and social implications of utilizing cane trash in the final crop year as a substitute for bunker oil appears promising. It represents an opportunity for developing biomass energy use in the Sugarcane industry as well as for industries / communities in the vicinity.
Positive socio-economic impacts include the provision of large-scale rural employment and the minimization of oil imports. It can also develop the expertise necessary to create a reliable biomass supply for year-round power generation.
Recovery of Cane Trash
Recovery of cane trash implies a change from traditional harvesting methods; which normally consists of destroying the trash by setting huge areas of sugarcane fields ablaze prior to the harvest. There are a number of major technical and economic issues that need to be overcome to utilize cane trash as a renewable energy resource. For example, its recovery from the field and transportation to the mill, are major issues.
Alternatives include the current situation where the cane is separated from the trash by the harvester and the two are transported to the mill separately, to the harvesting of the whole crop with separation of the cane and the trash carried out at the mill. Where the trash is collected from the field it maybe baled incurring a range of costs associated with bale handling, transportation and storage. Baling also leaves about 10-20% (1-2 tons per hectare) of the recoverable trash in the field.
A second alternative is for the cane trash to be shredded and collected separately from the cane during the harvesting process. The development of such a harvester-mounted cane trash shredder and collection system has been achieved but the economics of this approach require evaluation. A third alternative is to harvest the sugarcane crop completely which would require an adequate collection, transport and storage system in addition to a mill based cleaning plant to separate the cane from the trash .
A widespread method for cane trash recovery is to cut the cane, chop into pieces and then it is blown in two stages in the harvester to remove the trash. The amount of trash that goes along with the cane is a function of the cleaning efficiency of the harvester. The blowers are adjusted to get adequate cleaning with a bearable cane loss.
On the average 68 % of the trash is blown out of the harvester, and stays on the ground, and 32 % is taken to the mill together with the cane as extraneous matter. The technique used to recover the trash staying on the ground is baling. Several baling machines have been tested with small, large, round and square bales. Cane trash can be considered as a viable fuel supplementary to bagasse to permit year-round power generation in sugar mills.
Thus, recovery of cane trash in developing nations of Asia, Africa and Latin America implies a change from traditional harvesting methods, which normally consists of destroying the trash by setting huge areas of cane fields ablaze prior to the harvest. To recover the trash, a new so-called “green mechanical harvesting” scheme will have to be introduced. By recovering the trash in this manner, the production of local air pollutants, as well as greenhouse gases contributing to adverse climatic change, from the fires are avoided and cane trash could be used as a means of regional sustainable development.
Cane Trash Recovery in Cuba
The sugarcane harvesting system in Cuba is unique among cane-producing countries in two important respects. First, an estimated 70 % of the sugarcane crop is harvested by machine without prior burning, which is far higher than for any other country. The second unique feature of Cuban harvesting practice is the long-standing commercial use of “dry cleaning stations” to remove trash from the cane stalks before the stalks are transported to the crushing mills.
Cuba has over 900 cleaning stations to serve its 156 sugar mills. The cleaning stations are generally not adjacent to the mills, but are connected to mills by a low-cost cane delivery system – a dedicated rail network with more than 7000 km of track. The cleaning stations take in green machine-cut or manually cut cane. Trash is removed from the stalk and blown out into a storage area. The stalks travel along a conveyor to waiting rail cars. The predominant practice today is to incinerate the trash at the cleaning station to reduce the “waste” volume.
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