Decentralized Power Generation System from Crop Residue Presented at Conference on Innovation in Agricultural Mechanization by Anil Kumar Dubey Principal Scientist 7th- 8th July 2016 CENTRAL INSTITUTE OF AGRICULTURAL ENGINEERING NABI BAGH, BERASIA ROAD, BHOPAL-462 038

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 Residue Suitable for Power Generation Crop residues Agro-Industrial residues Cotton stalk Pigeon pea stalk Soybean stalk Mustard stalk Castor stick Maize stalk Millet straw Groundnut shell

Surplus Crop Residues in India 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

Availability of Crop Residues in Selected Districts of MP Burning of soybean stalk in Selected Districts

Potential of (100 kW) Power plant (Nos.) Crop residue Potential of (100 kW) Power plant (Nos.) Pigeon pea 68

Concept of Power Generation Collection and Transportation Briquetting Gasifier Plant Electricity Generation Domestic Activity Concept of Power Generation Crop Residues Agro Enterprises Production Activities

Technology Options   Gasification Thermo chemical Conversion Bio- Chemical Conversion Combustion Anaerobic digestion Heat utilized for steam generation - for turbine operation - Commercial above 1 MW  High calorie gas suitable for power generation Byproduct contains- NPK Gasification  Generation of P-Gas from reside Power though gas engines Power through dual fuel engine Suitable for small scales (10 - 500kW) Dual Fuel Mode Gas Engine

Considerations for Power Generation Biomass management (Fuel Supply Chain) Feedstock preparation (Briquetting) Generation of Fuel ( Gaseous) Electricity Generation Cost Benefit

Bales of soybean stalk Weight of one bale: 30 - 33 kg Biomass management 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

Collection of soybean stalk Average Yield: 733-844 kg/ha Manual collection: 330- 410kg/ha

Biomass management

Transportation cost at different lead distance

Collection Cost (Rs./tonne) Transportation cost (Rs./tonne) Biomass management Cost of Soybean Straw 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 *8 km lead distance; ** 40 km Lead distance; ***100km Lead distance

Biomass Management Issues Seasonal variability Low density and scattered Low level of mechanization Change in crop production pattern Conventional uses Logistics for collection and storage

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 Preparation of residues for Power Generation at Village Mana Raw Material used : Pigeon pea stalk, Lantana camera and Soybean straw.

Percentage Share of Cost of 60 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 Entrepreneurs development 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

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.

Value addition of soybean stalk Rs. 1220/tonne Rs. 1350/tonne Rs.450/tonne Collection + Briquetting Collection + Briquetting + Power generation Collection

Conclusions The crop residue based electricity generation system developed and demonstrated successfully in Village Mana. Electricity generation cost is at par with cost of grid power supply Technology has attracted local entrepreneurs for value addition of crop residues through briquetting. Value addition to crop residues by briquetting has shown impact on reduction in straw burning in field and economic gain to farmers and associated entrepreneurs.

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