6.2 Annex 2- Biomass resources availability‘Pakistan Renewable Energy Policy 2006’ covers the availability, mapping and policy forgeneration of power through various renewable energy technologies like hydro, solar, wind, etc.Further, the addendum to Renewable Energy Policy 2006 covers some specific points forbagasse/biomass based power plants. This draft policy document is prepared as an extendedversion of the existing policies covering the utilization of biomass resources for powergeneration in detail.The different types of biomass suitable for power generation are shown in the following diagram: Energy Crops Muncipal Agro Solid Wastes Industrial Feedstock for Waste Biomass Power Production Forest Agricultural Waste Wastes Figure 4: Feedstock for biomass power generation 21The resources considered and the sources of information for the development of this draft policydocument are as shown in the following table:Table 14: Source of information for the feedstock for biomass power generation in PakistanType of Description of the feedstock Source of information RemarksfeedstockAgricultural Waste generated from “Final Report on Biomass Nilwaste agricultural crops like straws, Atlas of Pakistan”21 “A r eview on biomass energy resources, potential conversion and policy in India”, Anil Kumar, NitinKumar, Prashant Baredar and Ashish Shukla, “Renewable and Sustainable Energy Reviews” Journal, Feb2015Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 51 of 59
Type of Description of the feedstock Source of information Remarksfeedstock husk, etc. developed as a part of the NilAgro Wastes generated from rice “World Bank Biomassindustrial mills, plywood industry, etc. Mapping for Pakistan: Nilwaste Phase 1-3” Parts of felled trees which are “Final Report on Biomass Not included, as it isForest waste not removed from the forest Atlas of Pakistan” developed as a part of the considered to be aMunicipal Biodegradable waste such as “World Bank Biomasssolid waste food and kitchen waste, green Mapping for Pakistan: subject for the medium / waste, paper, inert waste like Phase 1-3”Energy crops fabrics, clothes etc. “Scoping Phase Report” long term on account of developed as a part of the Plants exclusively grown for “World Bank Biomass the complexity involved their wood from marginal Mapping for Pakistan: lands for energy generation Phase 1-3” October 2014 in the technology Nil selection for efficient Nil conversion Not included, as it is considered to be a subject for the medium / long term on account of the need for a parallel policy development exercise on land utilization for energy plantationAgricultural wasteThe estimation of agricultural waste available for power generation is based on the cropproduction (available as per agriculture statistics) and factors the crop residue ratio (CRR) –, i.e.the ratio between the biomass produced and the crop production, competing use of biomassand willingness of farmers to sell the biomass. The sequence of steps by which the surplusbiomass is determined is shown in the figure below:Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 52 of 59
Step 1: Estimated annual crop production Step 2: Estimated annual biomass production (Based on crop residue ratio) Step 3: Estimated annual surplus biomass (Considering competing use and willingness of farmers to sell the biomass) Figure 5: Sequential steps for the estimation of surplus biomassStep 1: Estimated annual crop productionThe estimated annual crop production for Pakistan22 is as follows:Table 15: Source of Crops Produced in Pakistan Estimated crop production (‘000 ton) 65,257Crop 14,531SugarcaneCotton 34,581 16,754Wheat 4,260Rice 135,383MaizeTotalStep 2: Estimated annual biomass productionThe estimated annual crop production is multiplied with the crop residue ratio (individual valuesfor each type of crop) to arrive at the theoretical annual biomass production. The CRR is acharacteristic of each type of crop. The CRR values may differ from one information source toanother because of differences in understanding of the definition of the same. The differencesarise mainly because of looses during harvesting and transportation and storage. Such lossesinclude stumps of stalk left uncut for wheat, maize, mustard, etc. Part of the residue utilized forcaptive consumption such as cane green top as fodder is also not often accounted for whiledetermining available residue. CRR is also dependent on the type of soil, pattern of rainfall andharvesting season. It is, therefore, imperative to consider the CRR values for similar geographicconditions to arrive at the representative CRR.DESL’s database of CRR (especially for the studies conducted in regions close to the Pakistanborder in India), CRR from other literature survey (TERI – a study done for Patiala region in India22 Source: “Final Report on Biomass Atlas of Pakistan” developed as a part of the “World Bank BiomassMapping for Pakistan: Phase 1-3”Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 53 of 59
& UNEP – a study covering overall Pakistan) have been reviewed. These values differ from thefigures mentioned in the “Final Report on Biomass Atlas of Pakistan” as detailed in the belowtable:Table 16: CRR values from different sources Description of CRRCrop residue ESMAP Biomass DESL TERI study for UNEP database Patiala23 study24 Atlas2 0.3Sugarcane Trash 0.12 0.065 0.10 3.0Cotton Sticks 3.4 2.50 1.0 1.0 1.1Wheat Straw 1 1.17 1.2Rice Straw 1 1.42 1.15Maize Stalk 1.25 1.29 1.96The CRR values from the final atlas2 were considered for further analysis of power potential frombiomass.Step 3: Estimated annual surplus biomassThe above derived annual biomass production was adjusted loss due to consumption of biomassin other competing use and willingness of farmers to sell the biomass to derive the estimatedsurplus biomass. The following table summarizes the estimation of annual surplus biomassavailable.Table 17: Calculation of estimated annual surplus biomass productionType of Estimated CRR Source: Estimated annual Estimated annual surplus biomasscrop annual crop ESMAP Biomass biomass production ('000 ton) production Atlas ('000 ton) 2,552 ('000 ton) 5,039 5,689Sugarcane 65,257 0.12 7,831 6,534Cotton 14,531 3.4 49,405 680Wheat 34,581 1 34,581 20,494Rice 16,754 1 16,754Maize 4,260 1.25 5,325Total 135,383 113,89623https ://cdm.unfccc.int/Projects/DB/DNV-CUK1179324777.88/ReviewInitial Comments/OLEJNKZCUBK3FLFPWKGZNFB3NM64L024http://www.unep.or.jp/ietc/spc/a cti vi ties/GPWM/da ta/T3/AB_4_1_BaselineReport.pdfClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 5 -FinalReport Title Recommendations- policy on biomass gasification and combustion technology Page 54 of 59
Agro industrial wasteThe quantity of crop-processing residues generated as by-products of the agro-industrialprocesses in industries are called agro-industrial waste. The following table summarizes theestimation of annual surplus biomass (taking 100% collection efficiency).Table 18: Calculation of estimated annual surplus biomass productionType of Estimated Type of CRR Estimated annual Estimated annual surplus biomasscrop annual crop Residues biomass production ('000 ton) production ('000 ton) (taking 100% ('000 ton) collection efficiency)Sugarcane 65,257 Bagasse 0.30 19,557 19,557Rice 16,754 Husk 0.20 3,351 3,351Maize 4,260 Cob 0.33 1,406 1,406Maize Husk 0.22 937 937Total 86,271 25,271 25,271In addition to crop residues, wood based residue generated from the wood processing industryare also potential energy sources. Sawdust, slabs and chips generated as residues of woodprocessing are a valuable resource, which can be used as feedstock for energy generation. Woodprocessing residues are often readily available and considered a cheap resource; the level of theirutilization varies considerably. Assessment of wood based residue produced is based on annualsawnwood production, average efficiency of sawmills and current use of residues.25The amount of roundwood used for industrial purpose is 2,989,000 m3/year26. Considering 50%27residue production from wood processing industries, it is reasonable to consider about 1,494,500m3 of wood-based residue available for biomass power generation. Assuming 50%28 of theexisting residue being converted to feedstock for power generation, the annual amount of woodbased residue available is summarized in the below table:Table 19: Wood based residue Unit Value m3 747,250Particular g/cm3 1.5Volume of Wood based residue produced ‘000 ton 1,121Density29Surplus Wood Residue25www.fao.org/.../40588-06126445556b3b96080217e0ee63937a0.pdf26“Scoping Phase Report” developed under the “Biomass resource mapping in Pakistan” project by ESMAP,October 201427http ://w ww .bi oenergycons ul t.com/ta g/wood- wa s tes /28To be validated29http ://w ww .ti s -gdv.de/ ti s _e/wa re/hol z/rundhol z/rundhol z.htmClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 5 -FinalReport Title Recommendations- policy on biomass gasification and combustion technology Page 55 of 59
Forest harvesting residuesThe forest harvesting residues available are based on the annual round wood production, rate offelling removal and the percentage of the residues that are already used by the poor in villages tocarry out household activities. However, reviewed literatures do not provide reliable informationeither about the volume of wood harvested and processed, or about the processing efficiencyand level or residues utilization. Due to this, it is not possible to estimate whether there might beany available surplus residues.Summary of residues availableThe following table summarizes the surplus biomass available:Table 20: Total Surplus Biomass Available Surplus biomass for electricity generation (000 tons)Biomass Type 20,494 25,271Agricultural waste 1,121Agro industrial waste 46,886Wood Based Residue TotalClient Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 56 of 59
6.3 Annex-3 Business Case ExamplesCase Study # 1 Pa ki s ta nCountryI ndus tr y Rice MillContex t The plant generates 8000 MT/year rice husk every year, out of which about 3000Recommende MT/year was consumed in the steam generation plant and the remaining 5000 MT/yeard project of husk was sold. The use of the surplus rice husk for installation of a CHP system, to meet the power requirement was considered, keeping in view the increase in steam and power demand, with proposed gradual expansion of rice milling from 48,000 TPY to 99,500 TPY. The project configuration was developed based on the assessment of demand (daily variation, seasonal variation) with change in production, existing demand & supply situation for both electricity and steam, cost of electricity purchased and reliability, opportunity cost for sale of surplus rice husk. A modular scheme for expansion of the plant from 525 kW to meet current demand to 1,050 kW was proposed. The system recommended comprises a downdraft gasifier, with gas cleaning and gas engine. A biomass briquetting machine was recommended for fuel prepa ra ti on.Costs and The modular approach for implementation, would help in increasing the confidencebenefi ts O&M of the system. The investment estimate for the plant was PKR 145 million (2014 levels), which includes cost of plant machinery & equipment, structures and civil engineering works, pre- production capital costs and net working capital requirements. The gasification system and gas engine make up about 80% of the total investment. The operating costs includes the fuel cost and the O&M costs. Specific fuel consumption of 1.6 kg/kWh (vendor specification) was considered to estimate the variable cost. A market survey was carried out to assess the availability and price of supplemental fuel if required. Based on this, the direct fuel cost of power generation was estimated as PKR 14.68/kWh. This compares well against the weighted average cost of power (grid + diesel generation) incurred at PKR 24.68/kWh. The O&M cost was considered as per vendor specifications. The project is financially viable. The project IRR considering a discounting factor of 12.75% was 32% over 20 years with normal payback of approximately 5.12 years.Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 57 of 59
Case Study # 2 Pa ki s ta nCountryI ndus tr y Plywood manufacturingContex t The unit manufactures about 800,000 m2 of ply wood annually yielding about 250 t/y ofRecommende wood waste. In addition to the process electricity demand (about 100 kW), some amountd project of heat is also required in the process, which is provided using a thermic fluid heater. A Combined Heat and Power project was therefore conceptualized to help the unit independently meet the power and heat demands, using the wood waste generated. The project configuration was developed based on study of production patterns, electricity demand and corresponding heat requirements. Future growth in demand with increase in production was also considered. A 300 kW gasifer plant (wood chip based) with gas cleaning and engine was recommended which would be able to meet the full demand for power (either by extending hours of operation or through net metering arrangement with utility). While a single gasifer was recommended keeping in view future load, 3x 100 kWe engines wer e recommended to be added as and when the load requirement increased.Costs and Only 20% of the fuel demand for the project was met from the wood chips generatedbenefi ts internally. A fuel survey was therefore conducted to assess the availability and cost of fuel . The investment estimate for the plant was PKR 29 million (2014 levels), which includes cost of plant machinery & equipment, structures and civil engineering works, pre- production capital costs and net working capital requirements. The gasification system and gas engine make up about 80% of the total investment. The operating costs includes the fuel cost and the O&M costs. Specific fuel consumption of 1.4 kg/kWh (vendor specification) was considered to estimate the variable cost. A market survey was carried out to assess the availability and price of supplemental fuel if required. Based on this, the direct fuel cost of power generation was estimated as PKR 14/kWh. This compares well against the cost of power purchased from the grid incurred at PKR 22.77/kWh. The O&M cost was considered as per vendor specifications. The project was financially viable. The project IRR considering a discounting factor of 12.75% was 25.95% over 20 years with normal payback of over 6 years.Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 58 of 59
Case Study # 2 Punjab, IndiaCountryI ndus tr y Cosmetic manufacturingContex tRecommended The feasibility of installation of a biomass based power generation system was assessedproject to reduce the energy cost of manufacturing. The assessment involved a field survey ofCosts and biomass availability, selection of fuel, ascertaining the likely price and fuel logistics andbenefi ts project configuration. The current steam requirement of the plant is met by diesel fired boilers (1 x x 1.5 T, 2 x 0.6 T). It was suggested to incorporate biomass (pelletized rice husk and saw dust) based boilers. The proposed configuration on which detailed feasibility was carried out was as foll ows . Proposed Fuel Rice husk and Wood chips from biomass traders and s uppli ers Techno logy Combustion for steam generation Boiler design capacity 4 t/h (out of which 1.6 t/h for VAM and 2.4 t/h for Pr oc ess ) Vapor Absorption 400 TR Machine capacity Operation 300 days, 24 hours of operation with PLF of 75% Fluidized bed boilers were suggested as they have • ability to burn low-grade biomass fuels, due to the high thermal inertia and high turbulence of the fluidized bed • high combustion efficiency, due to the turbulent mixing of the fluidized bed and the long residence time of the fuel in the furnace • Compared to a boiler efficiency of 55-60% achievable with stepped grate furnace, the fluidized bed combustion technology offered will give a high efficiency of the order of 75-80%. Sized wood chips are also suitable fuel for fluidized bed technology. During interaction with suppliers it was found that the twin furnace design is also available for biomass fuels. Fluidized bed for rice husk and grate technology for wood chips, pellets and briquettes. This twin furnace design is suitable for rice husk and different biomass fuels. Based on boiler technology and fuel properties, appropriate flue gas cleaning system was selected. A combination of wet scrubber and cyclone was proposed. Vapor absorption machine was used to meet the process chilling load and the comfort cooling load in the industry. The requirement of cooling was estimated by the plant was 400 TR. In order to reduce the carbon footprint the cooling was catered by steam based VAM system. The total project cost for the proposed system was estimated to be INR 38 Million. The project had a payback period of 1 year.Client Name UNIDO DESL Project No. 9A0000005647Project NameReport Title Policy advisory services in Biomass gasification technology in Pakistan Version 5 -Final Recommendations- policy on biomass gasification and combustion technology Page 59 of 59
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