Potential Assessment of Energy Providing for Bagasse-Based Chipboard Industry Using Sugarcane Waste (A case study: Debal Khozaie Agro-Industry)

ماشین های کشاورزی

Article 8, Volume 12, Issue 2 - Serial Number 24, June 2022, Pages 193-206   

Document Type: Research Article

DOI: 10.22067/jam.v12i2.87600

Authors

E. Alboativi; A. Asakereh^* ; H. Zaki Dizaji; Y. Mansoori

Department of Biosystems Engineering, Faculty of Agriculture, Shahid Chamran University of Ahvaz, Iran

Abstract

Introduction: Bagasse is the dry pulpy fibrous residue that remains after sugarcane stalks are crushed for juice extraction. Bagasse is widely used in conversional and by-product industries. Bagasse is commonly used as a substitute for wood in many tropical and subtropical countries for the production of pulp, paper, and board. One of the most important conversional industries in the sugarcane agro-industry is chipboard production. In recent years, two chipboard factories from bagasse were exploited in Khuzestan province. In the production of chipboard from bagasse, a lot of waste is produced, most of which include pith. The waste is transferred to the outside of the factory at a great cost and energy level. Also, annually, a large amount of surplus bagasse of conversional Industries is obtained in Khuzestan agro-industries. These wastes cause many environmental and health problems, while these wastes can be used to generate energy. On the other hand, chipboard industries consume a lot of energy which is mostly fossil energy. Nowadays, in many sugarcane agro-industries in different countries, wastes are used to generate energy for sugar plants and conversional industries. Bagasse is often used as a primary fuel source for sugar mills.
Materials and Methods: Current research is focused on the direct energy consumed in chipboard production from sugarcane bagasse and whether it can be provided by using residues and wastes of Debal Khozaie Agro-Industry Company. Data were collected from agro-industry companies as well as by sampling and measuring waste, input and energy consumption at the chipboard factory of Debal Khozaie. Direct energy consumed in the chipboard production from bagasse includes diesel fuel, electricity, natural gas, and labor. Input and output values of materials (bagasse, pith, etc.), and energy consumption (electricity, diesel, natural gas, etc.) were collected using both laboratory tests and data available in agro-industry. Potential of energy generation from bagasse, pith, wood chips, and straw in Debal Khozaie agro-industry, were considered by the direct burning method. Also, the potential of biogas production from vinasse in agro-industry for energy production was calculated. The moisture of bagasse (fresh bagasse, 24 hours, five days, 30 days, and 45 days after gathering), outdoor dried pith, outdoor dried straw and wood chip were measured based on the ASTM D2974 standard method in the laboratory. Ash percentage of bagasse, peat, straw, and Wood chips were measured using a furnace, desiccator and a scale. Also, the lower heating value of bagasse, straw, pith, and wood chips were measured using a calorimeter bomb.
Results and Discussion: The direct energy consumption in the chipboard factory was determined to be 5.829 GJ m^-3 of produced chipboard. Natural gas and electricity were the major sources of direct energy with 78.52% and 18.87% share, respectively. To replace these sources, pith and woodchips form chipboard factory, sugarcane leaves, remainder sugarcane bagasse, and vinasse from molasses-based Razi alcohol factory were considered. Properties of the substituted resources were determined including ash, moisture content, heating value (using bomb calorimeter), and amount of woodchips along with the biogas potential from anaerobic fermentation of vinasse. Results showed that woody residues from chipboard factory and Debal Khozaie Agro-Industry Company had the potential to provide 4.33 fold the energy provided by gas in the chipboard factory, considering the efficiency equal to 60%. Using the residues of the chipboard factory individually, it is possible to replace all the consumed natural gas and electricity energy needed in the chipboard factory as well. According to the volume of available vinasse, the potential biogas production from this resource estimated to be 8.82 Gm³.
Conclusion: Electricity, natural gas, and diesel fuel constitute the direct energy consumed in the production of chipboard, and natural gas with 78.52% has the highest share. Electricity accounts for 18.87% of direct energy consumption. The specific energy of chipboard production at the chipboard factory was 5.829 GJ m^-3. Only using the pith of chipboard factory can produce 2.85 times the total energy of natural gas consumed in chipboard factory. Investigation of the potential of biogas production from vinasse in Debal Khozaie agro-industry showed that it is possible to generate energy equivalent to 8824.3 thousand cubic meters of natural gas. Overall, the study showed that using the wastes of chipboard factory and sugarcane agro-industry has the potential to replace the entire natural gas and electricity consumption in chipboard factory.

Keywords

Bagasse; Heating value; Pith; Sugarcane; Vinasse

References

1. Alena, A., and O. Sahu. 2013. Cogenerations of energy from sugar factory bagasse. Energy Engineering 1 (2): 22-29.
2. Andekaizade, A., M. J. Sheikh Davoodi, and M. Byria. 2018. Qualitative and quantitative features evaluation of two methods of sugarcane harvesting (with aim of energy and sugar production). Journal of Agricultural Machinery 8 (1): 212-221. (In Persian). http://dx.doi.org/10.22067/jam.v8i1.53629.
3. Anonymous. 2016. Energy Balance Sheet. Iran Ministry of Energy. Power and Energy Planting Department Publication. (In Persian).
4. 2018. Statistical Yearbook of agriculture. Statistical center of Iran. (In Persian).
5. Arshad, A., and S. Ahmed. 2016. Cogeneration through bagasse: A renewable strategy to meet the future energy needs. Renewable and Sustainable Energy Reviews 54: 732-737.
6. Baguant, J. 1984. Electricity Production from the Biomass of the Sugarcane Industry in Mauritius. Biomass 5: 283-297.
7. Birru, B., A. Martin, and C. Erlich. 2016. Sugar Cane industry overview and energy efficiency considerations, Stockholm: KTH Royal Institute of Technology.
8. Caputo, A. C., M. Palumbo, P. M. Pelagagge, and F. Scacchia. 2005. Economics of biomass energy utilization in combustion and gasification plants: effects of logistic variables. Biomass and Bioenergy 28: 35-51.
9. Dantas, G. A., L. Legey, and A. M. Mazzone. 2013. Energy from sugarcane bagasse in Brazil: An assessment of the productivity and cost of different technological routes. Renewable and Sustainable Energy Reviews 21: 356-364.
10. Demirbas, M. F., M. Balat, and H. Balat. 2009. Potential contribution of biomass to the sustainable energy development. Energy Conversion and Management 50: 1746-1760.
11. Evans, A., V. Strezov, and T. J. Evans. 2010. Sustainability considerations for electricity generation from biomass. Renewable and Sustainable Energy Reviews 14: 1419-1427.
12. Flausinio, B., A. Costa, R. Pinheiro, and A. Fortini. 2014. Theoretical Study about the Cogeneration Potential of the Bagasse Sugarcane at the Brazilian State of Minas Gerais. International Journal of Energy Science 4 (2): 35-42.
13. Fowler, P., G. Krajacic, D. Loncar, and N. Duic. 2009. Modeling the energy potential of biomass. International Journal of Hydrogen Energy 34: 7027-7040.
14. Halder, P. K., M. A. Hossain, N. Paul, and I. Khan. 2014. Agricultural residue for electricity generation in Bangladesh. Journal of Mechanical and Civil Engineering 11 (2): 89-95.
15. Haroni, S., M. J. Sheykhdavodi, and M. Kiani Deh Kiani. 2018. Application of artificial neural networks for predicting the yield and GHG emissions of sugarcane production. Journal of Agricultural Machinery 8 (2): 389-401. (In Persian). http://dx.doi.org/10.22067/jam.v8i2.52870.
16. Hasanaki, N., Y. Mansoori, and A. Asakereh. 2019. Potential of substituting bagasse for natural gas in Karun sugar factory and its economic evaluation. Iranian Journal of Biosystem Engineering 51 (1): 11-21. (In Persian).
17. Hasanaki, N. 2018. Technical and Economic Feasibility Study of Heat and Power Production in Karoon Sugar Factory Using a Hybrid System of Biomass, Photovoltaic, and Natural Gas. MSc thesis. Shahid Chamran University of Ahvaz. (In Persian).
18. Jadidyan, F., M. Talaeipoor, S. Mahdavi, and A. Hamasi. 2016. Evaluation of thermal energy and activated carbon production from bagasse pith. Iranian journal of Wood and Paper Science Research 31 (2): 181-193. (In Persian).
19. Janghathaikul, D., and S. H. Gheewala. 2005. Environmental assessment of power generation from bagasse at a sugar factory in Thailand. Energy 6 (1): 57-66.
20. Jezini, M. 2010. Investigating the effect of environmental conditions and optimization measures affecting the efficiency of thermal power plants. Journal of Electrical Industry 161: 38-44. (In Persian).
21. Karaj, S. H., T. Rehl, H. Leis, and J. Muller. 2009. Analysis of biomass residues potential for electrical energy generation in Albania. Renewable and Sustainable Energy Reviews 14: 493-499.
22. Kim, M., and D. F. Day. 2011. Composition of sugar cane, energy cane, and sweet sorghum suitable for ethanol production at Louisiana sugar mills. Journal of Industrial Microbiology & Biotechnology 38: 803-807.
23. Kitani, O. 1999. CIGR Handbook of Agricultural Engineering, Vol, V, Energy and Biomass Engineering. ASAE Publication, ST Joseph, MI.
24. Mashoko, L., C. Mbohwa, and V. M. Thomas. 2013. Life cycle inventory of electricity cogeneration from bagasse in the South African sugar industry. Cleaner Production 39: 42-49.
25. Mbohwa, C., and S. H. Fukuda. 2003. Electricity from bagasse in Zimbabwe. Biomass and Bioenergy 25: 197-207.
26. McKendry, P. 2002. Energy production from biomass (part 2): conversion technologies. Bioresource Technology 83: 47-54.
27. Mohlala, L. M., M. O. Bodunrin, A. A. Awosusi, M. O. Daramola, N. P. Cele, and P. A. Olubambi. 2016. Beneficiation of corncob and sugarcane bagasse for energy generation and materials development in Nigeria and South Africa: A short overview. Alexandria Engineering Journal 55: 3025-3036.
28. Mondal, M. A. H., and M. Denich. 2010. Assessment of renewable energy resources potential for electricity generation in Bangladesh. Renewable and Sustainable Energy Reviews 14: 2401-2413.
29. Moreira, J. R. 2006. Global biomass energy potential. Mitigation and Adaptation Strategies for Global Change 11 (2): 313-342.
30. Parsaee, M., M. Kiani, and A. Takdastan. 2018. Biogas production from sugar cane vinasse using a Static Granual Bed Reactor (SGBR). Fuel and Combustion 11 (2): 69-78. (In Persian).
31. Pellegrini, L. F., and S. Junior. 2011. Combined production of sugar, ethanol and electricity: Thermo economic and environmental analysis and optimization. Energy 36: 3704-3715.
32. Pourasad, K., A. Zali, M. Ganjkhanlou, A. Emami, and A. Hatefi. 2015. Effects of replacing molasses with sugar beet vinasse on performance, blood and ruminal parameters in Mahabadi kids. Journal Management Systems 3 (3): 11-21. (In Persian).
33. Ramjeawon, T. 2008. Life cycle assessment of electricity generation from bagasse in Mauritius. Journal of Cleaner Production 16: 1727-1734.
34. Rathnasiri, K., S. A. S. Senarath, A. G. T. Sugathapala, S. C. Bhattacharya, and P. A. Salam. 2005. Assessment of sustainable energy potential of non-plantation biomass resources in Sri Lanka. Biomass and Bioenergy 29 (3): 199-213.
35. Restutia, D., and A. Michaelowa. 2007. The economic potential of bagasse cogeneration as CDM projects in Indonesia. Energy Policy 35: 3952-3966.
36. Seabra, E. A., and I. Macedo. 2011. Comparative analysis for power generation and ethanol production from sugarcane residual biomass in Brazi. Energy Policy 39: 421-428.
37. Singh, J., B. S. Panesar, and S. K. Sharma. 2008. Energy potential through agricultural biomass using geographical information system-A case study of Punjab. Biomass and Bioenergy 32: 301-307.
38. Soleymani, M., A. Keyhani, and M. Omid. 2018.  Life cycle assessment, Ethanol, Sugarcane, Biofuel. Journal of Agricultural Engineering 40 (2): 13-27. (In Persian).
39. Tang, J., Zhu, K. Kookana, and A. Katayama. 2013. Characteristics of biochar and its application in remediation of contaminated soil. Journal of Bioscience and Bioengineering 116 (6): 653-659.