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Bagasse gasification to increase electricity generation in Cuban sugar mills
Conference Paper · August 2019
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Proceedings of the International Society of Sugar Cane Technologists, volume 30, 1673–1681, 2019
Peer-reviewed paper
Bagasse gasification to increase electricity generation
in Cuban sugar mills
Alejandro Fonte Pérez1, Junior Lorenzo Llanes2 and Meylin González Cortés3
1
Cuban Research Institute of Sugar Cane By-products (ICIDCA), Cuba; [email protected]
2
Faculty of Chemical Engineering, Technological University of Havana (CUJAE), Cuba
3
Faculty of Chemical, Central University of the Villas, Cuba
Abstract The possibility of increasing the current rates of electricity generation in the Cuban sugar mills,
using gasification schemes of sugarcane biomass, was evaluated by analyzing the integration
of bagasse gasification and combustion. A simulator was used to evaluate the thermal energy
system of a case study. A thermodynamic model for the sugarcane bagasse gasification in
Aspen plus v7.2 was developed. The results showed that it is possible to produce a synthesis
gas with a lower heating value of 4.71 MJ/kg, agreeing with other experimental results. Two
combined cycle alternatives were evaluated, showing that case 2 (combined-integrated cycle)
was the most attractive, with cogeneration and electrical efficiency values of 63.18% and
19.1%, respectively.
Key words Gasification, bagasse, combined-integrated cycle, simulation, Aspen
INTRODUCTION
Currently, the issue of energy is a global challenge. The availability of energy resources from fossil fuels is
limited, and, although there are different sources of energy, these fossil fuels continue to be the most widely used
form (Jittarat and Ratchadaporn 2011; AIE 2015). In recent years, this consumption has increased considerably,
generating an environment of uncertainty, due to the existing global reserve, its non-renewable nature and
concern about climate change (Jittarat and Ratchadaporn 2011; Doman 2013). Hence, the need to look for
viable alternatives from other sources of energy, which imply a lower environmental impact (Honty et al. 2010),
as is the case with the use of biomass (Jett 2011; Jittarat and Ratchadaporn 2011).
In Cuba, which is a predominantly agricultural and sugarcane-based economy, biomass resulting from these
activities offers real possibilities to achieve considerable increases in the generation of electrical energy, mainly
using sugarcane bagasse. However, the conventional technologies used are limited to converting less than 5%
of the bagasse energy into electrical energy, with the remaining 95% producing more steam than that required for
the sugar-production process (Valdés 2016).
In recent years, theoretical schemes have been proposed for the use of bagasse gasification in order to supply
synthesis gas to a gas turbine for the generation of electricity. Studies have explored the use of combined gas-
steam cycles to take advantage of the heat of the gas leaving the turbine in the generation of steam in a heat
recovery boiler and, consequently, generate more electrical energy (Valdés 2016).
International and national authors (Rentizelas et al. 2009; Ugalde 2012; Mavukwana et al. 2013; Copa et al.
2015) have addressed this issue of biomass gasification resulting in more efficient and cleaner process of
energy. Here, we use simulation to evaluate alternatives that allow the integration of the processes of
gasification and of combustion of the biomass.
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SIMULATION OF THE THERMOENERGETIC SYSTEM OF THE BASE CASE (CB)
Simulation of processes has been used to analyze alternatives that allow increasing energy efficiency in sugar
mills. It also allows mking changes in the production process and analyzing the profitability before implementing
them in the industry.
We consider a sugar mill that has a milling potential of 6,900 t/d of cane. There is a distillery attached with a
steam demand of 4 kg/s. There are three boilers, two with 16.7 kg/s and one with 12.6 kg/s at nominal capacity,
generating steam at 18.25 bar and 360°C. The superheated steam from the boilers is used in three
backpressure turbogenerators of 4 MW nominal capacity, which operate at 100% of the nominal load. The rest of
the direct steam is passed through a reducing valve (RV1), reducing the pressure to 2.4 bar and 126°C, to allow
for process demand fluctuations. To allow for fluctuations of demand in the batch pans there is a reducing valve
of 2.4 to 1.7 bar. The turbogenerator exhaust steam goes to the 2.4 bar line to feed the evaporation system
formed by a pre-evaporator and a quadruple and the clear-juice heater.
IMPROVED ALTERNATIVE CASE
We simulated an improvement alternative (CM) to increase the energy efficiency of the thermoenergetic system
of the CB. It considers changes that do not involve investment.
According to Rein (2007) the extra extractions in the first evaporators (effects) increase the evaporation capacity
of the multiple effects (or reduces the area required for the same flow). On the other hand, it is possible to use
steam from evaporators 1, 2, 3 and even 4 for juice heating. The changes that we propose for the CM are (Rein
et al. 2011):
• Change the configuration of the multiple effect (which was initially a simple and a quadruple effect) to a five
effect, to decrease the steam consumption.
• Perform a vapour extraction in the first effect to the clear juice heaters, and to the second evaporator.
• Perform vapour extractions in the second and third effect to meet the demands in the banks of secondary and
primary heaters respectively.
• Reduce the nominal load of a turbogenerator.
• Reduce the amount of water used in the vacuum pans for the dilution of the molasses, maintaining an
adequate control of the super saturation of the processed material.
SIMULATION OF THE PROCESS OF GASIFICATION OF CANE BAGASSE USING
ASPEN PLUS
We used the Aspen Plus software for the simulation of the gasification process. A series of steps were followed
in the simulation:
• Configure the simulation (units, report options, etc.)
• Define the components involved
• Define the method of physical properties by component
• Define the flow diagram: blocks and streams (usually done in the worksheet)
• Specify current data
• Specify the data of the blocks or modules used
The simulated process of a fluidized bed gasifier, equipment particularly advantageous for the biomass
gasification, is described below (Mavukwana et al. 2013; Arteaga et al. 2015).
The Aspen Plus simulator does not provide a particular module of a gasifier, so to simulate this process it is
necessary to separate it in different blocks of the different unit operations that are carried out in this process.
Figure 1 shows the simulation in Aspen Plus, of the gasification process of the surplus bagasse obtained in the
improved case.
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Figure 1. Aspen Plus simulation of the bagasse gasification process
The excess bagasse with 50% moisture (BAGS-M), which was obtained in the improved case, is fed as a non-
conventional component to a RStoic reactor (SEC). In this module the drying operation with hot air (AIR-SEC) is
carried out until 10% bagasse moisture is obtained, where a calculating block (WATER-CALCULATOR)
determines the fraction of water extracted from the bagasse in the output stream. Then this stream (BAGS-AIR)
passes through an SSplit (SEP) to separate the dry bagasse from the humid air. Subsequently, the dry bagasse
(BAGS-SEC) is decomposed into its constituting elements (C, H, O, N, H2O, S and Ash) in the pyrolysis stage.
For this, a RYield module (DESCOM) is used, where the calculations are based on the reaction yields of each
component, according to the last analysis of the bagasse and the mass flow of input to this module. The
calculations are made (by programming a subroutine in Fortran) in a calculating block (PIR-CALCULATOR). The
mixture obtained (CONV) in this block is separated into a SSplit (CHARSEP), where a portion of the
carbonaceous solid (CHAR-COM) passes to the simulated combustion stage in a RGibbs block (COMBUST),
using a chemical equilibrium model based on the minimization of Gibbs free energy. This allows, through the
restriction of temperature to reactions in the equilibrium, achieve a detailed description of the composition of the
gas, obtained experimentally. The excess air used in the combustion is calculated in a calculating block (COM-
CALCULATOR). Due to the endothermic character of the gasification, heat must be supplied to the system to
supply the thermal needs in the reaction stage. This heat is supplied by the combustion of the biomass (Q1).
The output current of the previous stage (PROD-COM) is mixed with the stream of the carbonaceous solid
(CHAR-GAS) in a Mixer (MIX1). This mixture enters the last stage, which is the gasification carried out in a
RGibbs (GASIFER) where steam is used as a gasifying agent. Finally, synthesis gas, also called syngas (GAS-
SINT) produced, is passed through a cyclone (GAS-SEPA) to separate the solids (ASH) contained in the gas
stream and obtain a clean gas (SINGAS).
According to the characteristics of Aspen Plus and the thermodynamic equilibrium model used in the simulation,
it is considered that:
• The system is adiabatic and operates in a steady state
• Particle size is not taken into consideration
• Heat losses in the reactors are not considered
• Ash contained in the bagasse is initially inert, so it does not participate in the chemical reactions that take
place during the stages of the process.
• Formation of tars in the pyrolysis stage is not considered.
VALIDATION OF THE PROPOSED MODEL
To perform the validation of the theoretical model proposed for the gasification process of the bagasse, the
simulated results obtained were compared with the values reported by Acevedo (2009) and Deshmukh (2008).
The type of biomass in both studies is the same (bagasse of sugarcane) with a similar analysis to what we used.
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To determine the accuracy of the model, the volumetric compositions obtained in the synthesis gas are compared
together with the temperature value at the outlet of the gasifier and the Lower Heating Values. Table 1 shows the
values of the ultimate analysis and other parameters taken from the literature and used in the model. Figure 2
summarizes the comparison of the synthesis gas composition we obtained with the data from the literature
(Deshmukh 2008; Acevedo 2009).
Table 1. Comparison of simulated results with experimental data reported by Deshmukh (2008) and Acevedo
(2009).
Ultimate analysis of bagasse (% dry basis) Deshmukh Acevedo Simulated
C 47 44.8 47.2
H 6 5.4 7
N 0 0.4 0
S 0 0.01 0
O 43 39.6 43.1
Parameters
Temperature (°C) 860 1,200 839
LHV (MJ/kg) 4.6 4.79 4.71
Figure 2. Comparison of the simulated synthesis gas composition with experimental values reported by
Deshmukh (2008) and Acevedo (2009).
The composition of hydrogen, methane and carbon monoxide is the key element in the adjustment, since these
components are what define the heating value of the gas and justifies the possibility of using gas in processes for
electric generation.
SIMULATION OF INTEGRATION ALTERNATIVES
For generating electricity generation systems from synthesis gas, there are different technologies that can be
used, such as gas turbines or the configuration that combines gas and steam turbines, known as a combined
cycle. Here, we describe the simulation in Aspen Plus of two case studies that include a combined cycle, starting
from synthesis gas obtained in the gasification process.
Case study 1: combined cycle with gasification
Case study 1 (CM-C1) consists of the coupling of two individual thermodynamic cycles, one that operates at high
temperature (Brayton cycle), which works with air-combustion gases, and another with lower working
temperatures (Rankine cycle) that works with steam. Figure 3 shows the simulation in Aspen Plus of the
combined cycle of case study 1.
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Figure 3. Simulation in Aspen Plus of the combined cycle of case study 1.
For a better energy use of the gas produced (SINGAS), it is mixed with compressed air (AIRCOMP) to be burnt in
a combustion chamber (CAMCOM) simulated by a RGibbs reactor. The compression of the air is simulated with
a Compr module, where atmospheric air is injected until compressed at a compression ratio equal to 15.9
(Rapum 1999). The gases resulting from isobaric combustion (COMBGAS) reach a temperature of 1200°C,
expanding in a gas turbine (TURB-GAS) simulated by a Turb module, to a pressure slightly higher than
atmospheric (1.06 bar) (Rapum 1999). Part of the energy becomes work (WTG) and the rest goes away with the
gases (RECH-GAS) (Rapum 1999; Çengel and Boles 2012). Afterwards, the exhaust flow from the turbine at
621°C according to what is reported in the literature (Copa et al. 2015), is collected in a heat recovery boiler
(taking advantage of its energy content) to exchange heat and generate steam (STEAM) at a given temperature
and pressure. This boiler is simulated jointly by two modules, since Aspen Plus does not have a single module
capable of simulating this process. This produced steam is conducted to an extraction-condensation steam
turbine (TURB-STEAM), where it expands and gives rise to the production of mechanical energy, which is used
to move an electric generator. Finally, the steam exhausted by the steam turbine (RECH-S) is condensed in a
condenser (COND) to be pumped back to the boiler, closing the cycle. The module used to simulate the pump
was Pump (PUMP) where the water enters as saturated liquid and is isentropically compressed up to the
operating pressure of the boiler (Çengel and Boles 2012).
Case study 2: integrated combustion-gasification cycle
The second case study (CM-C2) analyzed is a combined cycle based on the biomass gasification; its scheme is
shown in Figure 4 with differences to case 1 indicated.
The gasification of the bagasse occurs in the same way and under the same conditions as for case 1. In this
second configuration an extraction is made from the steam turbine (DEM-PRO) in order to satisfy the steam
demand of the distillery that is attached to the sugar mill. For this, an FSplit (SEP-STEAM) is used, whose
function is to combine the currents of materials (heat or work) dividing it into two currents, being able to specify
the amount of steam that is needed to extract according to the demand. Previously, the output conditions (2.4
bar) in the steam turbine (TURB-STEAM) are required to ensure that it complies with the required specifications.
Finally, the condensed steam (COND) is pumped back to the heat recovery boiler closing the cycle.
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Figure 4. Simulation in Aspen Plus of the combined cycle of case study 2.
Energy analysis of integration alternatives
There are different indicators that allow the energetic evaluation of thermodynamic systems with cogeneration.
Among the most used is energy efficiency.
Based on thermodynamic principles (first and second law), the performance of cogeneration units is measured
based on the use of the main source of energy, the fuel. A typical cogeneration system produces electrical
energy and useful thermal energy from the energy provided by a fuel. Therefore, the efficiency of the
cogeneration systems is defined as the ratio between the energy produced (thermal and electrical energy) and
the energy provided by the fuel.
To calculate the cogeneration energy efficiencies of the different case studies (CB, CM, CM-C1 and CM-C2) we
used equations 1 and 2 (Sabugal and Gómez 2006; Çengel and Boles 2012):
For the CB and CM individually:
𝑊𝑇𝐸𝑆 +𝑄𝑒𝑠𝑐
𝜂𝐶𝑁 = ∗ 100 Equation 1
𝐹𝑏𝑎𝑔 ∗ 𝐿𝐻𝑉𝑏𝑎𝑔
For the CM-C1 and CM-C2 individually:
𝑊𝑇𝐸𝑆 + 𝑄𝑒𝑠𝑐 + 𝑊𝐺𝑇 + 𝑊𝑆𝑇
𝜂𝐶𝑁𝐼 = ∗ 100 Equation 2
𝐹𝑏𝑎𝑔 ∗ 𝐿𝐻𝑉𝑏𝑎𝑔 + 𝐹𝑔𝑎𝑠 ∗ 𝐿𝐻𝑉𝑔𝑎𝑠
Electrical net efficiencies were also determined, using equations 3 and 4 (Sabugal and Gómez 2006; Çengel and
Boles 2012):
For the CB and CM individually:
𝑊𝑇𝐸𝑆
𝜂𝐸𝑁 = ∗ 100 Equation 3
𝐹𝑏𝑎𝑔 ∗ 𝐿𝐻𝑉𝑏𝑎𝑔
For the CM-C1 and CM-C2 individually:
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𝑊𝑇𝐸𝑆 + 𝑊𝐺𝑇 + 𝑊𝑆𝑇
𝜂𝐸𝑁𝐼 = ∗ 100 Equation 4
𝐹𝑏𝑎𝑔 ∗ 𝐿𝐻𝑉𝑏𝑎𝑔 + 𝐹𝑔𝑎𝑠 ∗ 𝐿𝐻𝑉𝑔𝑎𝑠
where: 𝜂𝐶𝑁 𝑎𝑛𝑑 𝜂𝐶𝑁𝐼 : energy net efficiencies of cogeneration, (%); 𝜂𝐸𝑁 𝑎𝑛𝑑 𝜂𝐸𝑁𝐼 : electrical net efficiencies, (%);
𝑊𝑇𝐸𝑆 : electrical net production of central TES, (kW); 𝑄𝑒𝑠𝑐 : heat that escapes from the turbines in the central TES,
(kW); 𝐹𝑏𝑎𝑔 : mass flow of bagasse consumed in the central boilers, (kg/s); 𝐿𝐻𝑉𝑏𝑎𝑔 : lower heating value of
bagasse, (kJ/kg); 𝑊𝐺𝑇 : net power generated by the gas turbine, (kW); 𝑊𝑆𝑇 : net power generated by the steam
turbine, (kW); 𝐹𝑔𝑎𝑠 : mass flow of synthesis gas produced in gasification, (kg/s); 𝐿𝐻𝑉𝑔𝑎𝑠 : lower heating value of
synthesis gas produced in gasification, (kJ/kg).
Based on the simulated results, Figure 5 shows the behavior of the cogeneration net efficiencies and electric net
efficiencies in the case studies.
70 63.01 63.18
59.79 58.59
60
50
40
%
30
19.17
20 15.25
10 2.22 0.92
0
CB CM CM-C1 CM-C2
Cogeneration net efficiencies Electric efficiences
Figure 5. Cogeneration net efficiencies and electric net efficiencies in the case studies.
The efficiency in the improved case (CM) decreases, due to the vapour extractions performed as explained in the
improved case, which causes a reduction in the factory steam consumption. These changes bring with it a
decrease in the electric generation, although the objective pursued is to increase surplus bagasse, for its later
use in the gasification process. The greater the amount of surplus bagasse, the larger the amount of synthesis
gas that is produced and the electricity generated. As shown in Figure 5, the highest cogeneration net efficiency,
63.18%, is obtained in the enhanced case integrated to the combined cycle of the second case study, similar to
values reported in the literature (Acevedo 2009; Woudstra et al. 2010; Copa et al. 2015). The efficiency of
cogeneration, the electric efficiency, is a criterion of significance, which allows to better appreciate the difference
between the alternatives. Figure 5 shows the results obtained for each alternative.
There is an obvious substantial increase in the alternatives of the bagasse gasification integrated to a combined
power cycle. Taking into account the amount of energy contained in the steam that leaves the exhaust of the low
temperature turbine, some is extracted, as explained in case study 2, in order to satisfy the demand of the
distillery. It has a steam demand of 4 kg/s, which is initially satisfied by the plant, with the exhaust steam from
the turbo generators at 2.4 bar and 126°C. With the extraction it is possible to reduce the use of process steam
to balance the factory towards a surplus of bagasse for cogeneration purposes. Then the bagasse passes to the
gasification stage and consequently to the combined cycle to generate power. That is why in the second case
study we obtained an efficiency value of 19.17%, higher than in the other case studies. These efficiencies reflect
the significant differences among the alternatives in the efficiency values of cogeneration, demonstrating with the
CM-C2 a better use of the caloric value contained in the bagasse for the generation of electrical energy.
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CONCLUSIONS
1. The thermoenergetic behavior of a base case was evaluated using the developed simulation tool that
determined the energy efficiency.
2. An improved alternative is presented to obtain a reasonable quantity of excess bagasse, for the subsequent
conversion into a fuel gas.
3. A thermodynamic model of a fluidized bed gasifier was obtained for the thermo-conversion of the remaining
bagasse, by means of the simulation in Aspen Plus v.7.2, and the model was validated with data reported in
the literature.
4. Two cases of electric power generation with a combined cycle were analyzed through the simulation in Aspen
Plus, based on synthesis gas obtained in the gasification process. The alternative proposed in the second
case study was the most attractive in terms of the best energy use in an integrated manner.
5. Based on the operating conditions of case studies 1 and 2, biomass gasification systems can be an important
alternative for the production of surplus electric power, allowing the commercialization of these to the national
electric power system. This would increase the sustainability of the sugar sector.
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Sabugal S, Gómez F. 2006. Centrales térmicas de ciclo combinado teoría y proyecto. Ediciones Díaz de Santos, Cambridge.
Ugalde R. 2012. Simulación en Aspen Plus del proceso de gasificación de residuo de hidrólisis enzimática de resina de pino.
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Valdés A. 2016. Residuos azucareros como fuente de combustible para la generación eléctrica. Boletín
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Gazéification de la bagasse pour augmenter la production d'électricité dans les sucreries
cubaines
Résumé. La possibilité d'augmenter les taux actuels de production d'électricité dans les sucreries cubaines à l'aide de
schémas de gazéification de la biomasse de canne à sucre a été évaluée en analysant l'intégration de la gazéification et de l a
combustion. Un simulateur a été utilisé pour évaluer le système d'énergie thermique d'une étude de cas. Un modèle
thermodynamique pour la gazéification de la bagasse de canne à sucre chez Aspen plus v7.2 a été développé. Les résultats
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ont montré qu'il est possible de produire un gaz de synthèse avec un pouvoir calorifique inférieur de 4,71 MJ/kg, ce qui
concorde avec les autres résultats expérimentaux. Deux alternatives de cycle combiné ont été évaluées, montrant que le cas 2
(cycle combiné intégré) était le plus attrayant, avec des valeurs de cogénération et de rendement électrique de 63,18% et
19,1%, respectivement.
Mots-clés: Gazéification, bagasse, cycle combiné intégré, simulation, Aspen
Spanish title Gasificación de bagazo para aumentar la generación eléctrica en los ingenios
azucareros cubanos
Resumen. La posibilidad de aumentar las tasas actuales de generación de electricidad en los ingenios azucareros cubanos,
utilizando esquemas de gasificación de biomasa de caña de azúcar, se evaluó mediante el análisis de la integración de la
gasificación con bagazo y la combustión. Se utilizó un simulador para evaluar el sistema de energía térmica de un estudio de
caso. Se desarrolló un modelo termodinámico para la gasificación de bagazo de caña de azúcar en Aspen plus v7.2. Los
resultados mostraron que es posible producir un gas de síntesis con un valor de calentamiento menor de 4.71 MJ/kg, de
acuerdo con otros resultados experimentales. Se evaluaron dos alternativas de ciclo combinado, mostrando que el caso 2
(ciclo integrado-combinado) fue el más atractivo, con valores de cogeneración y eficiencia eléctrica de 63.18% y 19.1%,
respectivamente.
Palabras clave: Gasificación, bagazo, ciclo combinado-integrado, simulación, Aspen
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