Opportunities for development of a Sugarcane Industry

Sugarcane as an Energy crop

Harold Davis and Paul Hough April 2006

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Prevailing Conditions
Caribbean Sugar Industries characterised by high cost Old Technologies, small factories and relatively high wages Traditionally dependent on preferential prices for raw sugar Significant price reductions from EU, the main preferential market
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Future of Sugarcane in the Caribbean

Raw sugar production can no longer sustain an economically industry

Exploit the total biomass of this unique crop

Electricity generation and ethanol will become increasingly important outputs from sugarcane production
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Features of Guyana Industry

With a production capacity of 320,000 tonnes at unit cost 18 per pound sugar, the Guyana Sugar Industry is probably the most competitive in the SAC group This Industry is also challenged by the new market prospects arising from the EU cuts Guysuco has developed a long term strategic plan for cost reduction based on expansion and improved efficiency.
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Guysuco-Strategy-1998
Expand Industry & Diversify Product Base Construct new 8400 tcd mill to produce refined sugar with co-generation of 10MW electricity Possible joint venture potable alcohol distillery at new factory Increase yields and reduce production costs on remainder of industry By 2010 sugar output 450,000 + tonnes
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Strategy Implementation
Strategy revolves around reduction in production cost to 12 per pound sugar Cost of operations largely dependent on labour intensive cane cultivation and harvesting Progress made with layout modification and reducing operating costs by increased mechanisation of agronomic practices Collaborating with WICSCBS in variety evaluation for energy and other potential uses 24 MPC varieties being propagated
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Characteristics DB 9633
DB 9633 120 tc/ha- Pl+2R Pol% cane 13% - 14% DB 7869 125 tc/ha Pl+2R Pol% cane ~ 12%

Fibre% cane 16%-18 % Fibre% cane 14% - 16%

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Skeldon Project Milestones

1999-Commence land development for new sugarcane project at Skeldon 2001-Booker-Tate appointed Project Manger 2002 -World Bank clearance for financing 2003- EIA and Env Permit approved 2004 Agreement for cogeneration component with Power Company and Financing bank 2005- Env Management Plan approved 2005- Factory Contracts signed 2006- Commence Factory Construction

Features of Skeldon Project

Net sugarcane cultivation to increase from 4270ha estate and 310ha farmers to 8700 ha estate and 4250 ha farmers Factory capacity 8400 tonnes cane per day Crop duration 27 weeks net! At steady state design capacity for 1,170,000 tonnes cane and and production of 110,000 VHP sugar

Features of Skeldon Project contd.

First diffuser in SAC industries Rum distillery under consideration as joint venture with Angostura Ltd. Factory will export 10MW to grid under firm power agreement Feasibility study and negotiations for refinery as joint regional venture in progress Refinery may be sited at alternative Berbice factory given Skeldons commitment to grid
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Cogeneration Plant Equipment

Two 125 tons/hr Boilers operating at 53 Bar and 485C Extraction/Condensing T/A output 15MW Back pressure T/A output 15MW Three Diesel Alternators combined output 10MW Heavy Fuel Oil for Diesel Alternators
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Plant Operating Features

Sugar factory power Process steam Cogen plant load Cogen plant steam Bagasse prod @ 34%cane Bagasse consumed in crop Bagasse storage 9900 kW 168000 kg/hr 2700 kW 5700 kg/hr 400000 t 320000 t 54000 t
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Skeldon Cogeneration operation

Projected 10MWexport power from bagasse fired boilers for 37 weeks to 40 weeks including 10 weeks out of crop from stored bagasse Projected 8MW export power from Diesel alternators when bagasse stock exhausted Supplementing stored bagasse with imports from Albion will extend out of crop generation period 6 week window of opportunity for fuel/mpc cane to supplement fuel supply to plant after juice directed to distillery.
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Energy Content of Sugar-cane (Guyana)

1 Tonne Cane

110 kg sugar 1800MJ 170 kg stalk fibre 3100MJ 140 kg top fibre(trash) 2600MJ Tot. 7500MJ 1 tonne cane approx. equivalent to 1 barrel of oil
(ex Dr. M. Regis Leal -2003)

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Fuel Potential of Sugarcane

Potential for leaves and tops to contribute to boiler fuel These should be removed prior to process for efficient extraction of sugars and fermentables Cellulosic materials associated with alkali and alkaline earth ions which can induce slag formation and reduce boiler efficiency Bagasse has advantage over other cellulosic fuels because extraction and washing removes significant amounts of alkalis and alkaline earths

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Meeting electrical requirements with back-pressure turbogenerators (at constant steam demand)
1,7 1,6 1,5 1,4 1,3

Specific electricity demand (kWh/t beet or cane)

mst Pel

import power

export power

Specific steam demand (% on beet or cane)

1,2
1,1 1,0 0,9

0,8
0,7

0,6
0,5 0,4

%
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
Electrical self-sufficiency (100 %) and generation of excess power for export (above 100 %)

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Power Characteristics Integrated Factory with Annexed Distillery Front end consumption Process consumption Pot export @45 bar 444C Pot export @ 82 bar 525C Distillery consumption ~ 21kwh/t cane 8 kwh/t cane 92kwh/t cane 143kwh/t cane 4kwh/t cane

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Cogen Potential 4800TCD Case Study

Cane Production -``````926100t 5MW Plant 47kwh/t cane 10 MW Plant 95kwh/t cane 12 MW Plant 113kwh/t cane 15 MW Plant 142kwh/t cane Implies a 15 MW facility can probably be supported
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Possible Sugar & Ethanol Production Guyana Pol% cane 11%, Purity 81%
Standard Process EtOH from final molasses only- sugar 9% cane, EtOH 10l/t cane A strike only sugar 6.1% on cane, EtOH 25l/t cane A & B strike sugar 7.6% on cane, EtOH- 17l/t cane Ethanol only 60l/t cane to 66l/t cane

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Ethanol Research 2002 -2004

4800 TCD factory could produce 74000 tonnes sugar and 11.3 M Liters of Ethanol 11.3 M Liters ethanol will permit 10% substitution in Gasolene Ethanol production from factory generated molasses and fuel cane indicated to cost between 12 to 14 per Liter Import price of Gasolene in 2003 - 24 per Liter Gasolene spot price reached 37 per Liter in June 2005
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Production 4800 TCD Case Study Sugar Ethanol (a) Cogen 5MW (b) Cogen 12 MW 73409t 11.3M liters 42GWh 105GWh

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Study Conclusions
Integrated production of sugar, ethanol and energy as electricity offered best economic potential from a factory of 4800 TCD capacity. Fuel ethanol rapidly growing market possibilities including import substitution by gasolene blends and export High fibre energy cane has potential role in extending crop to periods of weather disruption for power and ethanol production
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Commercial Ethanol prospects

Full feasibility to be conducted for a 12M liter fuel ethanol distillery from non contract molasses Strong interest expressed by investors in a 130M liter fuel ethanol project from sugarcane on green field site This project could support a 30MW cogeneration facility
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Planned Future Projects

Guysuco future plans include expansions of Enmore, Blairmont and Albion factories to capacities of 4400 to 5100 tcd. Enmore is planned to be the focus of branded packaged sugar. Albion is being considered as an alternative site for a refinery The expanded Enmore and Albion factories would have cogeneration capabilities with minimum exports of 7MW
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Next Steps
Feasibility of Proposed factory expansions Full Feasibility Study of Integrated Production Model inclusive of ethanol production Support for national commitment to renewable energy with recognition of the role of sugarcane
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THANK YOU FOR YOUR ATTENTION

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