Alternativas para las industrias

1. +1

2. Agenda
1. Caracterização da cana de açúcar
2. Projeções de produção de cana de açúcar no Brasil
3. Evolução das impurezas minerais
4. Evolução das impurezas vegetais
5. Evolução da demanda de energia elétrica
6. Participação do bagaço da cana de açúcar na matrix
energética nacional
7. Ponderações

3. IMPUREZAS
VEGETAIS
• Ponteiro
• Folhas Verdes
• Folhas Secas
Colmos
Açúcar
Etanol
ELETRICIDADE
A Energia da Cana de Açúcar
+
608 x Mcal/tc
Bagaço
com 50% umid.
598 x Mcal/tc
Palha
com 15%
512 Mcal/tc
=>
=>
+

4. Projeção de Processamento
634 676 719 763 808 853 898 944 990 1.037
Milhõestc
Fonte: Companhia Nacional de Abastecimento

5. Impurezas Minerais
5
7
9
11
13
15
17
19
21
Abril Maio Junho Julho Agosto Setembro Outubro Novembro Dezembro
Impurezas Minerais
(Kg/tc)
Méida safras 06;07 e 08 Safra 09 Safra 10Média Safras 06, 07 e 08
Fonte: GEGIS - Grupo de Estudos em Gestão Industrial do Setor Sucroalcooleiro

6. Impurezas Minerais
 Média Usinas Brasileiras (GEGIS): 10 kg/tc
 Safra de 632 Mtc => 6,32 Mt IM base seca
 Densidade Média IM: 1,75 t/m³
 Volume IM: 3,61 Mm³/ano
1,4 Pirâmides
de Quéops
ao ano
Pirâmide de Quéops
Volume Pirâmide ... 2,57 Mm3

7. Impurezas Vegetais
30
40
50
60
70
80
90
Abril Maio Junho Julho Agosto Setembro Outubro Novembro Dezembro
Impurezas Vegetais
(Kg/tc)
Méida safras 06;07 e 08 Safra 09 Safra 10Média Safras 06, 07 e 08
Fonte: GEGIS - Grupo de Estudos em Gestão Industrial do Setor Sucroalcooleiro

8. PARTICIPAÇÃO EFETIVA DAS FONTES DE ENERGIA NA MATRIZ
Fonte: ANEEL - Banco de Informações de Geração
80%
9%
Bagaço
de Cana
18.516 GWh
4%
3%
2%
1%
1%
7%
2010: Geração de 18.500 GWh, proveniente do bagaço da cana de açúcar - 2,1 GWm (8.760 h)
Matriz Energética Brasileira

9. PARTICIPAÇÃO DA BIOMASSA DA CANA
EVOLUÇÃO DA OFERTA DE ENERGIA ELÉTRICA
Hidroelétricas
PARTICIPAÇÃO %
3,7 TWh
7,7 TWh
18,5 TWh
Histórico Geração de Energia Elétrica no Brasil
Outros
Nuclear
Bagaço de Cana
Óleo & Gás
Hidro
349 TWh
403 TWh
504 TWh
87%
84%
80%
1% 2% 4%
76%
100%
2000 2005 2010
Fonte: MME – Ministério de Minas e Energia – Séries Históricas

10. Premissas – Projeção da Bioeletricidade
Hidroelétricas
 100% Bagaço voltado a produção de energia termelétrica
 Processamento de 33% palha da cana de açúcar para energia
 Garantias físicas concedidas
 Potência equivalente c/200 dias efetivos de safra
 Caldeiras 67 bar x 520oC
 Combinação de turbinas de Contra Pressão e Condensação
 Processamento de cana de açúcar:
 Moagem safra 2015/16 ... 808 Mtc
 Moagem safra 2020/21 ... 1.037 Mtc

11. Potencial Energético da Cana de Açúcar

12. Ponderações
 Fim das queimadas, no estado de São Paulo
 Evolução da mecanização agrícola
 Processo de difusão na extração
 Alongamento do período de safra
 Operação durante o período de entressafra
 Aumento das impurezas minerais
 Aumento das impurezas (?) vegetais
 Aumento da demanda de energia elétrica no Brasil
 Forte tendência de utilização de fontes renováveis de energia
 Crescimento do setor sucroenergético:
• Novas fronteiras
• Formação da mão de obra
• Formação dos canaviais

13. Fontes
 MME - Ministério de Minas e Energia - Séries Históricas
 MME/EPE – Plano Decenal de Expansão de Energia 2020
 ANEEL - Agência Nacional de Energia Elétrica - Banco de
Informação de Geração
 CONAB – A Geração Termoelétrica com a Queima do Bagaço de
Cana de Açúcar no Brasil
 CTC – Biomass Power Generation, Sugar Cane Bagasse and Trash
 GEGIS – Grupo de Estudos em Gestão Industrial Sucroalcooleira
 Monografia/ESALQ – Aproveitamento Agroindustrial do Palhiço
da Cana de Açúcar

14. Histórico das Caldeiras Dedini
ZANINI
ZANINI
M. DEDINI
D.Z.
Metalúrgica
DEDINI
Licença Zurn p/ Fab. Caldeiras
Licença Foster Wheeler

15. Fornecimentos
 Caldeiras a Bagaço ......................................... 1.255
 Caldeiras Industriais ................................... 393
 Caldeiras a biomassa, exceto bagaço ....... 3
 Plantas de Cogeração ................................... 114
Total de Caldeiras ...................... 1.651
Obs.: dados até dez/2010

16. Histórico das Caldeiras Dedini
1920 - FUNDAÇÃO “OFFICINAS DEDINI”
1930 - CALDEIRA DEDINI VERTICAL E FOGOTUBULAR
1940 - CALDEIRA AQUATUBULAR TIPO BABCOCK E STIRLING
1945 - CONTRATO COM COMBUSTION ENGINEERING
1951 - CALDEIRA ZANINI
1960 - PROJETOS DEDINI (V 2/4, V 2/5)
1977 - CONTRATO COM FOSTER WHEELER
1979 – CONTRATO COM ZURN – GRELHA ROTATIVA
1981 - CALDEIRA DEDINI - BMP E AT
1985 – CALDEIRA ZANINI - AZ/ZANITEC
1989 - SELO ASME - FABRICAÇÃO E MONTAGEM (S, U, PP)
2000 – CALDEIRA COGEMAX MULTICOMBUSTÍVEL PARA COGERAÇÃO
2001 – CALDEIRA AT E AZ ATÉ 250 t/h E GRELHA FLAT PIN HOLE
2005 – CALDEIRA AT-SINGLE DRUM ATÉ 400 t/h E 120 bar

17. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e1
Envirotherm in General
ENVIROTHERM
→ an experienced and qualified engineering partner
→ with an extensive list of references and
→ strong growth based on a portfolio of
proprietary technologies acquired from LURGI
CLEAN ENERGY
CLEAN AIR
(Air Pollution Control - APC)
Modern
Gasification Technologies
Highly Efficient
Flue Gas Cleaning
Technologies
Multi-Purpose
Combustion Technologies
Production and Application of
Honeycomb SCR Catalysts

18. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e2
Cooperation and License Agreements
 SCR Catalysts Production
 SCR-Process
• Joint Venture with Dongfang Boiler Group,
Chengdu, Sichuan, China
• Dongfang, SSEP for SCR process in China
• Cooperation with ERC GmbH, Germany
 FB/CFB – Power Plants
• Cooperation with the Slovak Boiler Manufacturer SES, Tlmače
• DEDINI, Brazil, for fluid bed technologies
 Clean Air Activities
• Jeongwoo, for ESP in Korea
• Longking, SSEP, TFEN, DATANG Group
for fabric filter in China
• VT Corp for ESP in India
 Gasification
• Shriram epc, India, fluid bed (CFB) and
fixed bed (BGL) gasification
• Collaboration with CEMEX on CFB gasification in the Cement
Industry (industrial know-how from Ruedersdorf facility)
• University of Clausthal-Zellerfeld, Germany
• CUTEC Institute – R&D in CFB gasification
CleanEnergyCleanAir

19. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e3
Clean Combustion Technologies:
BFB and CFB

20. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e4
• Bubbling and Circulating Fluidized Bed Technologies are a highly accepted
base technologies in utility and other industries for combustion of coal,
(high/low rank), biomass and various residual materials (sludges, RDF).
• Fluidized Beds represent proven and reliable technologies with numerous
reference plants and excellent emission values.
• Downstream technologies for dry dedusting (Electrostatic Precipitator and
Fabric Filter) are available with Envirotherm and are designed in accordance
with the latest environmental laws/directives.
• BFBs cover the lower capacity range of steam production,
CFBs are available for larger units.
• Both Fluidized Bed Technologies offer their specific advantages for their
specific range of application.
Fluidized Bed Combustion:
Available Technologies

21. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e5
• Increase in moisture content (up to 65%):
lower heating value, resulting in higher amount of flue gas
• Increase in chlorine content (up to 0,05%):
high potential for „High Temperature Chlorine Corrosion“ in boilers without
appropriate design
• Increase in content of impurities/ash (up to 10%):
to be considered in boiler and equipment design
• Increase in sulphur content (up to 0,05%):
use of limestone required in order to meet legal SO2 emission limits
All future challenges mentioned will be met
by our BFBs and CFBs
New Bagasse = New Challenge

22. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e6
• Use of primary air for fluidization and of secondary air for complete
combustion as well as for enhanced temperature and emission control
• Injection of fuel directly into the bed via several feeding points in order to
support a homogeneous energy input across the combustor cross section
• Proven fluidizing nozzles with low pressure drop,
but even air distribution
Bubbling Fluidized Bed (1)

23. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e7
• Flue gas recirculation for temperature control in case of varying fuel qualities
(e.g. season / off-season)
• Bottom ash discharge via multiple openings in the fluidization nozzle grate or
via an „open“ nozzle grate in case of high impurities / tramp material content
• Co-combustion of various fuels is
possible, when considered during
boiler design
Bubbling Fluidized Bed (2)

24. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e8
• Coarse ash classification and re-feed into the BFB combustor in case of
• high amount of ash in the fuel and
• low amount of alkalines in the fuel ash
• Desulphurization is possible via limestone injection
• Operable load range between 50 and 100%
• Application in the lower capacity range
• High reliability due to
• simple and robust design
• good temperature control: avoids agglomerations
• design of coarse ash discharge with sufficient margins
Bubbling Fluidized Bed (3)

25. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e9
Circulating Fluidized Bed (1)
Basic Principles of CFB Combustion
• Intense and turbulent mixing of solid fuel,
air and flue gas
• Uniform system temperature: no peaks,
no agglomerations
• No HP-steam bundles in the ash stream:
no bundle erosion
• Low and controlled combustion
temperature due to Fluidized Bed Heat
Exchanger technology
• Generous residence time:
excellent carbon conversion
• Optimum conditions for multiple fuels;
variation of fuel shares feasible during
operation

26. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e10
Circulating Fluidized Bed (2)
Basic Flow Sheet of a CFB Boiler

27. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e11
• Optimum and stable combustion conditions for lowest emissions
• Efficient sulphur capture in the CFB combustor by limestone injection
• Low NOx emissions due to
• low combustion temperature
• low excess air ratio
• staged combustion
• Partial capture of chlorine and fluorine
in the CFB combustor
• High boiler efficiency due to
• low excess air
• high carbon burnout
• no flue gas recirculation
Circulating Fluidized Bed (3)
Emissions and Efficiency

28. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e12
Fluidized Beds: Comparison
Clean and reliable combustion technologies showing excellent
features with respect to emissions, efficiency and future bagasse
Feature
Bubbling
Fluidized Bed
Circulating
Fluidized Bed
Emissions NOx  
CO  
Dust  
SO2 Capture  
HCl and HF Capture  
Combustor Cross Section  
Complexity of Combustion System  
Particle Residence Time  
Uniformity of Combustion Temperature  
min. Part Load Capabilty  
Boiler Efficiency  
Ability of Firing Varying Fuel Qualities  
Ability to Cope with "New Bagasse"  
CAPEX  
OPEX  
Status of Technology  

29. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e13
“As a participant in Simtec 2011 ENVIROTHERM is very
pleased with the introduction of our technologies into the
Brazilian market, and we reaffirm our complete confidence in
the potential and performance of the Fluidized Bed Boilers.”
“Our partnership with DEDINI reinforces this confidence, and
guarantees that all the advantages of the Fluidized Bed
Boilers will be fully exploited to the benefit of the Brazilian
sugar, ethanol and bioelectricity market.”
Werner-Fr. Staab, ENVIROTHERM GmbH

30. ENVIROTHERM
P r o f e s s i o n a l C o m p e t e n c e14
Obrigado!
for your attention
Envirotherm GmbH
Werner-Fr. Staab
Head of Sales (Thermal Processes)
Ruhrallee 185 D–45136 Essen Germany
werner_staab@envirotherm.de
www.envirotherm.de

31. Lançamento
2011
LANÇAMENTO DAS CALDEIRAS COM LEITO FLUIDIZADO
&