Decentralized Power Generation System from Crop Residue
CENTRAL INSTITUTE OF AGRICULTURAL ENGINEERING NABI BAGH, BERASIA ROAD, BHOPAL-462 038
by
Anil Kumar Dubey Principal Scientist
Presented at
Conference on Innovation in Agricultural Mechanization
7
th- 8
thJuly 2016
Issues to be discussed and needs answer
• Is there any crop residues available?
• What are the residues suitable for power generation?
• How much residues are available for power generation?
• How to use these crop residues for power generation?
• What are the technology options available for power generation?
• How to establish fuel supply chain to power plant?
• Cost Economics
Highlights of power production status in India:
• Installed capacity (April2016): 302833 MW
• Power generation
• Thermal : 69.8%
• Hydro: 14.1%
• Renewable : 14.2%
• Peak power shortage: 19 %
• Average Power shortage: 12%.
• Transmission & distribution Loss: 29-34%
• Electricity - production (billion kWh): 1090851
Crop Residue Available in India
Production : 500 MT
Surplus Crop Residue : 133 MT
Potential for power generation : 16,000 MW
Crop residues Agro-Industrial residues
• Cotton stalk
• Pigeon pea stalk
• Soybean stalk
• Mustard stalk
• Castor stick
• Maize stalk
• Millet straw
• Groundnut shell Crop Residue Suitable for Power Generation
Soybean
2% Cotton
21%
Pigeonpea 1%
Others 76%
Surplus Crop Residues in India
Crop
Residue kt/year
Cotton 28.0
Soybean 3.0
Pigeon pea 1.0
Others 101.0
Total 133.0
Burning of Crop Residues
Estimates of Burning: 70-90 Million tonnes
Case Study
Surplus crop residues in MP
Soybean 19%
Cotton Pigeon pea 37%
3%
Others 41%
Crop residues kt/year Soybean 1893.4 Cotton 3775.9 Pigeon pea 308.0 Others 4102.3 Total 10079.6
Availability of Crop Residues in
Selected Districts of MP
36.2
12.2 9.73 9.7
11.81 9.7 13.3
39.1
0 5 10 15 20 25 30 35 40 45
Sehore Seoni Bhopal Raisen
Selected districts
Soybean stalk (kt/year) Burnt
Collected
Burning of soybean stalk in Selected Districts
Surplus c rop residue: Udaipura
Pigeon pea 59%
Others 41%
Biomass Status: Raisen District
148.7
60.9
112.0
99.0
39.8
244.3
51.6
11.1 30.1 21.4 9.6
64.1
0 50 100 150 200 250 300
Udaipura Silwani Raisen Goharganj Begumganj Barelly Taluk
Quantity, kt/year Generation
Surplus
Crop residue
Potential of (100 kW) Power plant
(Nos.)
Pigeon pea 68
Collection and Transportation
Briquetting Gasifier Plant
Electricity Generation
Domestic Activity
Concept of Power Generation
Crop Residues
Agro Enterprises
Production Activities
Technology Options
Thermo chemical Conversion Combustion
Gasification
Heat utilized for steam generation - for turbine operation
- Commercial above 1 MW
Generation of P-Gas from reside
• Power though gas engines
• Power through dual fuel engine
• Suitable for small scales (10 - 500kW)
Bio- Chemical Conversion Anaerobic digestion
• High calorie gas suitable for power generation
• Byproduct contains- NPK
Dual Fuel Mode
Gas Engine
Considerations for Power Generation
1) Biomass management (Fuel Supply Chain) 2) Feedstock preparation (Briquetting)
3) Generation of Fuel ( Gaseous) 4) Electricity Generation
5) Cost Benefit
Bales of soybean stalk
Weight of one bale: 30 - 33 kg
Time for one bale production : 2-2.5 min
Bales per hectare: 24- 28 Nos
Biomass management
Collection of soybean stalk
Average Yield: 733-844 kg/ha
Manual collection: 330- 410kg/ha
Manual harvesting + manual collection Combine harvesting + manual collection Combine harvesting + Bailing Operation
38 40 42 44 46 48 50 52 54
43.33 43.1
51.43
Av. collection cost (Rs./tonne)
Biomass management
5km 40km 100km
0 200 400 600 800 1000
225
417
842 Cost /tonne
Lead Distance
Transportaion Cost Rs/tonne
Transportation cost at different lead distance
Intervention Collection Cost
(Rs./tonne) Transportation
cost (Rs./tonne) Total
Cost (Rs./tonne)
Threshed straw +
manual collection 500 225* 725
417** 917
842*** 1342
Combine harvested straw + manual collection
431 340* 771
476** 907
941*** 1372
Combine harvested straw + Baling
Operation
514 180* 694
317** 831
727*** 1241
Cost of Soybean Straw
*8 km lead distance; ** 40 km Lead distance; ***100km Lead distance Biomass management
• Seasonal variability
• Low density and scattered
• Low level of mechanization
• Change in crop production pattern
• Conventional uses
• Logistics for collection and storage
Biomass Management Issues
Biomass Supply Chain
• Power plant (100kW) would require 4-5 collection centers
• One collection centre between two villages
• Collection centre capacity: 250-300 tonnes
• Minimum storage space : 1000 sq-m with raised plate form
• Machines required: shredding machine and tractor trailer
Preparation of residues for Power Generation at Village Mana
Feed stalk Preparation
Raw Material used : Pigeon pea stalk, Lantana camera and Soybean straw.
Percentage Share of Cost of 60 mm Diameter Briquettes
Percentage Share of Cost of 90 mm Diameter Briquettes
Case Study: Use of briquettes in Brick Kiln
Capacity of kiln: One Lakh bricks
Fuel Used : 10 tonne hard coal
Cost of Fuel : Rs 80000/- (@Rs 8 /kg)
Briquettes requirement to replace Coal: 14 tonnes
Cost of briquettes: Rs 49000/tonne (price @ Rs 3.5 /kg)
Savings: Rs 31000/-
Reduction in CO2 emission
Impact of Briquetting Technology
Capacity : 1500 kg/h
Production of Briquettes : 20 tonne/day
Biomass required : 6000 tonne/annum
Employment (man-days)
For collection : 6000-7000
For Handling & Loading : 2000
For production : 1500
Direct Mandays : 9500-10500
Reduction in burning area : 6000 hac.
Wood Saving : 5500 tonne
Coal Saving : 4000 tonne Reduction in CO2 emission
Benifits of Technology
Benefits to the farmers
Employment opportunity
Additional income @ Rs. 400-500 per tonne realized by selling agro residues.
Benefits to industries/ entrepreneurs
Organized biomass fuel market available
Uniform size and quality fuel is available Benefits to financial institutions
Good scope for micro-financing to the rural entrepreneurs for establishing briquetting and/ or setting up of biomass based power under decentralized mode
Environmental Benefits
Carbon neutral fuel
Reduction in emissions
Establishment of Power Plant at Mana
• Briquetting Plant : 500kg/h
• Power Plant: 62 kVA - Three Number
One plant used for production of briquettes
Second plant for running the water pump of 50 hp(1 No)
Third plant used for running 3 Nos of water pump (30hp)
Supply of electricity to Municipal Corporation Raisen and adjoining farmers
Entrepreneurs development
View of Power Plant Installed at Mana
Power generation
The gas produced is supplied to diesel engines to replace 80%
diesel consumed by diesel generating set.
These diesel engine runs with 20 % pilot injection of diesel for ignition of producer gas. The fuel used to produce one unit of electricity is 60-70 ml of diesel and 1.0 kg of wood chips to produce one unit of electricity. Fuel Cost Rs 6.7
The cooled & cleaned gases are supplied to modified CNG engines to produce the electricity. The biomass consumed to produce the one unit of electricity varied from 1.2-1.3 kg of briquettes. Fuel Cost Rs 3.2
Economic impact of Technology
Supply of loose Biomass
Crop residues supply to briquetting plant: Rs 1500 per tonne Farmers Expenditure:
for collection Rs 300-400 per tonne
for transportation : Rs 400- 500 per tonne Net Profit : Rs 400-500 per tonne
Briquetting of Crop Residues
Value addition by briquetting : Rs 3500 per tonne.
Expenditure on preparation of briquettes: Rs 500 - 550 per tonne.
Net Profit to entrepreneur : Rs 1000-1400 per tonne
Costs of electricity generation
Gasifier based power plant: Rs 6.50-7.0 per kWh
Diesel engine generator: Rs 15.0-16.0 per kWh.
Grid supply: Rs 7.0 per kWh(com. Rate) Employment Opportunity
• 4000 man days per annum
• Reduction in burning: 1200 hectare (soybean crop )
Major benefits
Assured availability of electricity from their own local resources which were considered as waste and creating environment pollution.
Rs.450/tonne
Rs. 1350/tonne
Rs. 1220/tonne
Collection Collection + Briquetting
Collection + Briquetting
+ Power generation
