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International Journal of Sustainable Energy

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Performance analysis of a rice husk power generating system: a case study

Anis Afzal , Mohibullah Mohibullah & Virendra Kumar Sharma
a a a b

Faculty of Engineering and Technology, Aligarh Muslim University, Aligarh, India

b

Bhagwant Institute of Technology, Muzaffarnagar, India

Available online: 06 Jan 2011

To cite this article: Anis Afzal, Mohibullah Mohibullah & Virendra Kumar Sharma (2011): Performance analysis of a rice husk power generating system: a case study, International Journal of Sustainable Energy, 30:1, 1-10 To link to this article: http://dx.doi.org/10.1080/14786461003802100

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International Journal of Sustainable Energy Vol. 30, No. 1, February 2011, 110

Performance analysis of a rice husk power generating system: a case study

Anis Afzala *, Mohibullah Mohibullaha and Virendra Kumar Sharmab
a Faculty

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of Engineering and Technology, Aligarh Muslim University, Aligarh, India; b Bhagwant Institute of Technology, Muzaffarnagar, India
(Received 18 October 2009; nal version received 22 March 2010 )

One biomass energy source is rice husk, which is a very promising renewable energy source as it is an indigenous, cheap, and clean source of energy. However, environmental and nancial proles of electricity generation from rice husk must be assessed to ensure reduction in greenhouse gas (GHG) emission and positive cash ow. GHG emission from a rice husk generating system is signicantly less than that from fossil fuel power plants. A dual-fuel diesel engine-generator of 800 kW, using a rice husk gasier, is considered for this analysis. This paper presents a comprehensive analysis of a traditional energy technology in a new perspective. The results of simulation data analysed in terms of pollution through GHG emissions, nancial aspects, and suitability of the scheme for underdeveloped villages in economically developing nations are critical contributions of the paper. It also indicates the expected energy generation from the rice husk available in the region. Keywords: dual-fuel generation; energy model; gasication; greenhouse gas emission; renewable energy; rice husk

1.

Introduction

Biomass is one the most important energy sources among renewable energies (REs). It is third among the primary energy sources after coal and oil (Werther et al. 2000). In India, rice is a major cereal, is nearly 40% of the total food grain cultivated, and is cropped in over 30% of its area. Indias share of world rice production is nearly 21%. Rice husk and rice bran are byproducts when its edible form of paddy is processed. Rice bran is used for oil extraction and in feed formulations, whereas husk is generally used as fuel to generate heat for paraboiling of paddy and in other applications. The use of husk in industry involves difcult handling and bulky transportation because of its low density of 11244 kg/m3 (Kandpal and Garg 2003). Onsite use of rice husk in industry may be achieved to avoid transportation and carriage as average husk production from rice mills is 187 kg/tonne paddy (Jain 2006, Ahiduzzaman 2007). Techniques of conversion of husk into electricity and heat energy at relatively higher efciencies are available.
*Corresponding author. Email: anis_afzal@hotmail.com

ISSN 1478-6451 print/ISSN 1478-646X online 2011 Taylor & Francis DOI: 10.1080/14786461003802100 http://www.informaworld.com

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The potential of biomass to meet global energy demand is well known. In India, foreign exchange on import of fossil fuel and conservation of the limited supply of fossil fuel widely depend upon utilization of all other indigenous fuel energy sources. Therefore, biomass has become an alternative energy source for developing countries like India, where the economy is based on agriculture and forestry. In the USA, according to the Department of Electricity, electricity generation from biomass accounts for the largest source of non-hydroelectric renewable generation. It is expected that by 2025, biomass will continue its dominant role in electricity generation and electric capacity addition among RE sources. The Indian railway has already started using biomass in the form of biodiesel in its engines and is aiming to replace up to 10% of its diesel with biodiesel (Ghayur 2006). In northern China, a four-in-one model of biogas has been successfully developed in households. It typically includes the following: a greenhouse in the courtyard; a piggery and a toilet beside the greenhouse; and a biogas digester below the piggery and toilet. The four components greenhouse, piggery, toilet, and biogas digester constitute a four-in-one model (Wang 2004). However, the environmental impact of the rice husk energy power plant may be evaluated using life cycle methodology. Energy, material, and carbon balances may be determined for tracing system ow. The environmental impact of rice husk energy plants is mostly less than that of fossil fuel plants (Chungsangunsit et al. 2004). Biomass releases carbon dioxide when it is converted into energy. But because biomass absorbs carbon dioxide during sunlight hours as it grows, the entire process of growing, using, and re-growing biomass results in very low to zero carbon dioxide emissions (Bull 2001). Ashraf et al. (2008) have reported a general mathematical model for RE of a remote place like an island with two objective functions, namely cost and environmental pollution that work reversibly. A Pareto set is derived from the proposed mathematical tool, satisfying the multiplicity of criteria, namely environmental pollution, energy demand, per-unit generation cost, and resource constraints (Ashraf et al. 2008). For this work, simulation software Renewable-energy and Energy-efcient Technologies Screen (RETScreen) is used to obtain results in the form of simulated data called the energy model, which is analysed in terms of pollution through greenhouse gas (GHG) emissions, nancial aspects, and suitability of the scheme for under-developed villages in a developing nation like India. The expected energy generation using available rice husk in the region is also evaluated.

2.

Biomass gasication

Biomass gasication is thermo-chemical conversion of solid biomass into a combustible gas mixture (producer gas) through a partial combustion route with air supply restricted to less than that theoretically required for full combustion. Biomass gasication is basically conversion of solid fuels like wood, wood-waste, agricultural waste, rice husk, rice straw, etc. into a combustible gas mixture called producer gas. Pyrolysis is thermal degradation either in the complete absence of an oxidizing agent, or with such a limited supply that gasication does not occur to an appreciable extent or may be described as partial gasication. A relatively low temperature of 400450 C is employed (Ankur Scientic Energy Technologies Private Limited,ASETPL 2010), compared with 8001000 C in gasication. Three products are usually produced: gas, pyrolysis oil, and charcoal, the relative proportions of which depend very much on the pyrolysis method, the characteristics of the biomass, and the reaction parameters. Fast or ash pyrolysis is used to maximize either gas or liquid products according to the temperature employed (Khan 2009). A chemical reactor is used as the gasier in which various complex physical and chemical reactions are carried out. Biomass materials are allowed to pass through different processes in order for drying of the biomass, pyrolysis, combustion, and reduction. There is signicant overlap between any two consecutive processes, although each section/zone is designed for a particular

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process where chemical and thermal reactions take place. The biomass to be converted into producer gas must pass through all the zones. Gasication is a highly efcient process the efciency ranging from 70% to 85% (ASETPL 2010). The process can be applied over a range of 5850 kWe, which may be used for generating power and thermal applications in ovens, furnaces, kilns, hot air generators, dryers, boilers, etc. (Kirubakaran et al. 2009, ASETPL 2010). For direct thermal applications from producer gas, the important factor of the caloric value (CV) should be considered. The CV of producer gas is in the range of 510 MJ/kg (Ravindranath et al. 2004, Khan 2009), whereas for diesel the value is in the range of 4546 MJ/kg (Khan 2009). Therefore, from a heating viewpoint, a larger quantity of biomass is required to be burnt to get same amount of energy as compared with diesel. Depending upon the degree of cleanliness, a gasier can work in three modes, namely hot gas mode, scrubbed mode, and ultra clean mode. In the hot gas mode, the gas is neither cooled nor cleaned before burning, whereas in the case of scrubbed mode the gas is cleaned and cooled. In the case of ultra clean mode, the gas is further cleaned to a very high degree in a series of lters after coming from the scrubber. In any one of the modes of application, 1.0 l of oil can be saved through the use of either approximately 5.5 kg of rice husk or 3.54 kg of wood (ASETPL 2010).

3. Availability of rice husk In India, paddy is cultivated in all the states, particularly West Bengal, Andhra Pradesh, Uttar Pradesh, Punjab, Orissa, and Karnataka, which are leading states. Production of rice and husk is shown in Table 1. Form these states, total production of paddy is more than 50% of that of all of India. Approximately 9294% of gross cropped area is used to crop 8690% of gross production of paddy during JulyOctober (Kharif season). Average productivity of paddy in November April (Rabi season) is 1.5 times that of Kharif. The availability of rice husk depends upon the production of paddy, production process, and husk-to-paddy ratio which ranges from 0.14 to 0.27.
Table 1. Production of rice and husk in 20072008 in India. Production States West Bengal Andhra Pradesh Uttar Pradesh Punjab Orissa Karnataka Tamil Nadu Chhattisgarh Assam Bihar Haryana Maharashtra Madhya Pradesh Jharkhand Gujarat Kerala Others All India Rice (in megatonne) 14.51 11.70 11.13 10.19 6.86 5.74 5.22 5.01 3.55 3.50 3.21 2.70 1.66 1.56 1.30 0.63 3.32 91.79 Husk (in megatonne)a 3.337 2.691 2.560 2.344 1.578 1.320 1.201 1.152 0.816 0.805 0.738 0.612 0.382 0.359 0.299 0.145 0.764 21.112

Source: Indian Council of Agricultural Research Data 2009. a 1 tonne of paddy produces 0.813 tonne of rice and 0.187 tonne of rice husk (Ahiduzzaman 2007).

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The total energy potential depends on CV and the quantity available. Paddy is processed into rice for consumption with nearly 10% paddy being retained for seed and other uses (Kandpal and Garg 2003).

4.

Rice husk power generating system

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A biomass gasier-based power generation system mainly consists of gasier, a cooling and cleaning unit, and a dual-fuel engine-generator set as shown in Figure 1. The moisture content of rice husk ranged from 8.68% to 10.44%, and energy available ranged from 14 MJ/kg to 16 MJ/kg (Jain 2006, Khan 2009). Different biomass materials need different gasication technology and equipment (ASETPL 2010). Generally, a xed bed gasier is suitable for gasifying high apparent density biomass materials, for example, wood and cornstalk, etc. In India rice husk gasication is mostly carried out in a xed-bed down draft gasier (Khan 2009), whereas in China the gasication of loose materials such as rice husk, rice straw, wheat straw, sawdust, and combustible municipal waste is generally carried out in a cone-shaped uidized bed gasier of a mild steel structure with a reactor of conical shape at the bottom end, which is famous (Zhang 2004). Rice husk is fed from the hopper at the top of the structure and heated either in the absence of oxygen or by partial combustion in restricted air or oxygen. The products of pyrolysis are usually a mixture of gaseous fuel, namely hydrogen (H2 ) 1520%, carbon monoxide (CO) 1820%, carbon dioxide (CO2 ) 9 12%, methane (CH4 ) 15%, and nitrogen (N2 ) 4555%, an oil-like liquid called pyrolytic liquid (water soluble phase including acetic acid, acetone, methanol, non-aqueous substances, oil, and tar), and nearly pure carbon char (Khan 2009). Normal water is pumped into the lower portion of the reactor to remove char which is taken out to a drain tub. The cooling and cleaning unit consists of a venturi scrubber and a separate box with a cloth lter. The venturi scrubber is used to cool the producer gas and to remove coarse particulates. The drain box and separation tank are used for removing and separating char and water. The coarse lter removes tar, particulates, and moisture from the gas, which are taken to a drain tub. Fine dust particles are removed through separate ne lters in one or two stages. The ultra clean gas is mixed with air, before it is injected to the cylinder of the engine coupled with a generator set to replace the liquid diesel fuel. In dual-fuel generation, a pilot quantity of

Figure 1.

Block diagram of duel-fuel/100% producer gas power generation.

International Journal of Sustainable Energy

liquid fuel is injected towards the end of the compression strokes to start combustion. In a typical dual-fuel engine, 7075% of the diesel oil may be replaced by producer gas and the remaining 2530% energy comes from diesel oil (ASETPL 2010). The objective of the present case study is to frame an energy model of a system generating electrical energy from rice husk, which is available in abundance in the area where the system is to be installed. One of Indias reputed gasier manufacturers, ASETPL, makes producer gas from rice husk generating systems using a very small percentage of diesel oil as the pilot quantity. Therefore a detailed analysis of a generating system is prepared using 2% diesel oil as the pilot fuel. Similarly, 100% producer gas may also be suggested to replace all the diesel oil. A number of important factors like type of gaseous fuel, performance and design, and other parameters are to be considered for proper selection of the engine (Sahoo et al. 2009).

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5.

Case study of a biomass project

A case study of generation of electricity by rice husk is carried out for an industry, namely Hind Agro Industries Limited (HAIL), located in Cherat village, in the District of Aligarh, State of Uttar Pradesh in Northern India. The village is not connected to the utility grid and is surrounded by agricultural land where paddy is cultivated, which makes husk availability very easy. HAIL is the rst company in India to have one of Asias most modern abattoir-cum-meat processing plants. It is a joint venture of Hind Industries Limited and the Government of Uttar Pradesh and assisted by the Government of India. For the purpose of converting the existing single fuel A set into a dual fuel engine-generator set, a detailed study is executed for one of the eight different diesel generator (DG) sets used in the plant for the sake of the trial. A biomass gasier plant is proposed to be installed, making producer gas the main fuel for the engines. An uninterrupted electricity supply, for 24 h a day, is required for HAIL for production as well as for its cold rooms and cold storage. The electricity supply is fed from four DG sets, each of 1000 kVA/800 kW, out of which three sets run continuously and one is kept as standby. There are other four 500 kVA/400 kW DG sets; two DG sets run for 24 h and the other two are kept as standbys. There are refrigeration loads of 2000 tonnes, efuent treatment plant of 250 kW, rendering a plant of 1000 kW, lighting, and other loads. The consumption of diesel oil is 140 l/h for the 1000 kVA and 80 l/h for the 500 kVA engines. Therefore consumption of diesel is 580 l/h, that is, 13,920 l/day. A biomass power project is planned to run one of the DG sets of 800 kW for which a biomass gasier is to be installed. The latest RETScreen Software Version 4 is used for the purpose of analysis and feasibility-check of a dual-fuel engine using rice husk producer gas as the main fuel and diesel oil as the pilot fuel.

6.

Software analysis of the project model

The RETScreen Software is the leading tool specically aimed at facilitating pre-feasibility and feasibility analysis of RE technologies (RETs). The software is designed with the contribution of different experts from government, industry, and academia. The latest software Version 4 was designed and developed in 2007 for various types of RE and RETs. For this study, Method 1 is carried out because of the limited requirement of analysis and the simplicity of the method. A detailed analysis may be obtained from Method 2, if required. On the Energy Model page, availability of the proposed case power system may be selected either in hours or in percent of hours per year. Availability of new power systems is generally in the range

6 Table 2.

A. Afzal et al. Energy model for proposed biomass system. (Indian Rupees indicated as RS in this table)

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from 8000 h to 8400 h or from 91.3% to 95.9%. A practical mean value of 92% is considered. Older plants have less availability due to more maintenance and shut downs. In fuel selection, either single or multiple fuels in monthly or percentage mode may be opted for. Rice husk/hull as main fuel (98%) and diesel as a pilot fuel (2%) are considered. If a 100% producer gas is required to run an engine, single fuel mode is to be chosen. Market rates of both fuels are entered as shown in Table 2. The market price of rice husk varies signicantly from place to place and from time to time, that is, Indian Rupees (INR) 1.50/kg to INR 3/kg depending mainly upon transportation cost; whereas the diesel price is nearly same throughout India. A suitable dual-fuel engine of Energy Conversion make, model CAT 399 is chosen for a power capacity requirement of 800 kW as per site condition. Manufacturer and model number of the engine are selected as per the product

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database. Incremental initial cost, that is, total market cost of the dual-fuel engine and gasier along with other accessories, is estimated as INR 11,000,000 (NEDA 2008). The heat rate is the amount of energy input from the fuel to produce 1 kWh of electricity. It may be taken as 9600 kJ/kWh. This value may be judged from the typical heat rate curve for reciprocating engine between power capacity in kilowatts and heat rate for low heating value for 800 kW. The model calculates the fuel required per hour based on the power capacity and heat rate, which is 7.7 GJ/h. The electricity generated by the proposed system is utilized as per the site requirement. The rate to be paid for the usage per kilowatt hour of energy from the utility grid in the absence of the proposed system would have been according to the set tariff. The present electricity rate of the utility grid of INR 3/kWh is considered to compare the economical aspect of the proposed system with the utility grid (UPPCL 2008).

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7.

Emission analysis

Emission analysis of the dual-fuel diesel set using rice husk is performed on the basis of type of fuel used in the based case power system, which is coal here. Coal-based thermal generation is considered as base because most electricity generation is carried out in coal-based plants in the state of Uttar Pradesh, India. Transmission and distribution (T&D) losses of the base case are taken as 25% (UPPCL 2008). The T&D losses of the proposed case power system for the electricity exported from the dual-fuel generator set to the air conditioning and other plants is assumed as zero per cent, as these installations are very closely located to the generating unit. Like water vapour, CO2 , CH4 , ozone (O3 ), and nitrous oxide (N2 O), GHG in the earths atmosphere permit the passage of incoming solar radiation but prevent outgoing radiation from earth to space. This causes trapping of infrared radiation from the sun, which results in warming of the earths surface, that is, about 0.20.3 C over last 40 years, compared with about 0.30.6 C since the late nineteenth century (Yang 2004). Therefore, reduction of GHG emission has become a vital issue to save earth from global warming. In the present case, the reduction in net annual GHG emission is evaluated as equal to10,168 tonnes of CO2 (tCO2 ). The model calculates the gross annual reduction in GHG emission estimated to occur if the proposed system is implemented. The calculation is based on emission of both the base case which is coal-based thermal generation, and the proposed case system on an annual basis. Annual GHG reduction saving is evaluated as INR 10,168,369 by properly selecting the approximate value of GHG reduction credit rate as per international market INR 1000/tCO2 , that is, US$ 20/tCO2 (NEDA 2008, ET 2009). The rate varies between US $1 and US $35/tCO2 , widely depending upon how the credit is generated and how it is to be delivered. In India, a major portion of generated power comes from thermal power plants using coal as fuel, making it base case generation. Therefore power generation using rice husk comes within the framework of the Clean Development Mechanism, different from those generated from other type of projects using fossil fuels, outlined by Kyoto Protocol 2003, which was rst diplomatic document to combat climate change (Yang 2004). During its entire life of 20 years, total reduction in CO2 emission and saving will be 203,360 tCO2 and, INR 203,367,380 which is in favour of generation by rice husk. GHG reduction credit duration typically represents the number of years for which the project receives GHG reduction credits. It is used to calculate the GHG reduction income over the project life of 20 years. If a crediting period of 10 years is opted for, once the project has been validated and registered, the project may be issued a certicate from Certied Emission Reductions to go for another 10 years. The GHG reduction credit escalation rate, in per cent, is the project annual average rate of increase in the GHG reduction credit rate over the project life. This permits the user to apply rates

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Figure 2.

Cumulative cash ows graph.

of ination to the value GHG reduction credit rates. This value is taken as equal to rate of general ination of 8.98%t (ET 2009).

8.

Financial analysis and cash ow

This analysis is done on the basis of nancial parameters like ination rate, project life, debt ratio, debt interest rate, and debt term. An ination rate of 8.98% is used for nancial analysis, which uctuates according to the market prices of general commodities and is evaluated every week. The project life of 20 years is selected, which depends upon nancial feasibility, life expectancy of the energy-related equipment, and debt term or the duration of the power purchase agreement. In this analysis, the debt ratio indicates the nancial leverage created for the project. The higher the debt ratio, the larger the nancial leverage will be. The value of debt ratio is required to calculate the equity investment that nances the project. This value should be in the range of 090% with 5090% the most commonly used value (RETS 2010). A mean value of debt ratio of 70% is chosen. The debt interest rate is the annual rate of interest to be paid to the debt holder at the end of each year of the term of debt. Its value may also be taken as 8.98%, the same as the ination rate. The debt term is considered for 15 years, which is 5 years less than the expected life of the proposed system. The initial cost of the proposed system, complete with the cost of dual fuel generator, gasier, separation tank, lters, blower, valves, foundation platform, piping work, wiring, etc. is taken as INR 11,000,000 and a lump-sum amount of nearly 8.3% is evaluated for installation and other charges. Therefore, total initial cost may be taken as INR 12,000,000. As shown, the total annual costs come out to be INR 19,37,558. Total annual savings and income, and nancial viability are evaluated. The total annual savings and income are INR 29,510,449. Cumulative cash ow may be visualized by the cash ow graph as shown in Figure 2. The cash ow is positive as equity starts payback just after 0.3 years, that is, less than 4 months. However, the biomass energy system is found to be the cheapest and cleanest form of energy considering all other RE system options available; it becomes unfeasible only when biomass price hikes are exceptionally high (Afzal et al. 2010).

9.

Conclusion

Installation of dual-fuel generation not only provides energy at lower cost but at the same time reduces GHG emission. The following predictions may be made to judge the feasibility of the

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proposed system: In the case study system, a very small quantity of 2% of diesel oil is used as a pilot fuel. The main fuel, rice husk, is available in plenty in the surrounding rural area where the proposed system is suggested to be installed, which is unconnected with the utility grid. Therefore, the precious fossil fuel, diesel, is saved for some other purpose. In the proposed case of dual-fuel generation of 800 kW, net annual GHG emission reduction is 10,168 tCO2 . This is equivalent to 2067 cars and light trucks not used or 4,134,309 l of gasoline or 21,113 barrels of crude oil not consumed in 1 year. Therefore, during its entire life of 20 years, the proposed system is able to save GHG emission of 203,360 tCO2 . In the case of 100% producer gas generation of electricity, net annual GHG emission is 10,258 tCO2 , which is less than the emission of 98% producer gas generation of 10,168 tCO2 . In its entire life of 20 years, the 100% producer gas system will save 205,160 tCO2 . Income from GHG reduction in 1 year is estimated as INR 10,168,369, which is sure to rise further as GHG reduction credit, that is, the carbon credit rate is bound to enhance in the near future. There will be a GHG emission reduction income of INR 203,367,380 in the entire life of 20 years of the proposed system. The total annual savings and income from the proposed case is INR 29,510,449. Simple pay back time is 1.1 years and equity payback is 0.3 years. Cumulative cash ow is positive throughout from 0 years to 20 years, which indicates that the proposed system is nancially feasible. For generating 1 kWh energy, between 1.4 kg and 1.8 kg of rice husk is required in the dual fuel mode depending upon the percentage of pilot fuel quantity or 1.8 kg in 100% producer gas system (ASETPL 2010). In the state of Uttar Pradesh, India, in 20072008, rice husk produced was 2.560 megatonnes. A total energy of 1,828,571 MWh could have been generated from rice husk in the dual fuel mode in 1 year or 1,422,222 MWh in the 100% producer gas mode. Similarly, in the same year in India, 21.112 megatonnes of rice husk was produced, which could have generated 15,080,000 MWh energy in the dual fuel mode or 11,728,888 MWh in the 100% producer gas mode. Acknowledgements
The authors wish to thank Mr P.N. Pandey, Engineer, and other ofcials in the local ofce of the Non-Conventional Energy Development Authority (NEDA), a Government of India organization, Aligarh, for their valuable contribution for providing different data for this paper. This would have not been possible without their suggestions.

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