Product characteristics of fuel pellets

 Product characteristics of fuel pellets

 

1. Rod pellets

The basic ingredients of these pellets are corn stalks, wheat straw, rice straw, peanut shells (4644 kCal / kg), corn cobs, cotton twigs, soybean stalks, weeds (weeds), twigs, leaves, sawdust, and plant waste. other. After the raw material is crushed, then pressed, and molded, it is formed into a pellet shape by applying pressure between the rollers and the dies to the material. The density of the original material was around 130kg / m3, but the density of the pellets increased to over 1100kg / m3, making it easier to store and transport, as well as increase in burn performance.

2. Sawdust Pellets

Sawdust pellet production line: raw material purchasing, material gathering, drying, pelletizing and packing. The water content of sawdust is around 30-45% and the raw material price is around 21.05 - 24.29 USD / ton. The caloric value can reach 4,000 - 4,500 kCal

3. Twig Pellets

Branch pellet production line: raw material purchasing, crushing, drying, pelletizing and packing. Raw material costs ~ 16.19 USD / ton. The caloric value of twig pellets is lower than sawdust pellets.

 4. Bagasse pellets

Production procedures: purchase of raw materials, drying, pelletizing and packing. The quality of the material depends on the planting period. All ingredients can be stored efficiently in time, then dried, and pelletized. The water content in sugarcane is around 20-25%. Bagasse pellets have a high calorific value of 3,400-4,200 kCal (before being pelleted it is only about 1,825kCal, and if the raw bagasse is only heated using exhaust gas from the kettle chimney, the waste water content drops 40%, and the calorific value becomes 2305kCal).Bagasse pellets (bagasse) are a new bioenergy. It can be used as space heater, stove, hot water and industrial boilers, PLTBm, and others. It functions as a substitute for firewood, coal, fuel oil, and LPG. Bagasse has high energy content and high fuel quality. Unfortunately, the ash content is ~ 6%.

Bagas Pellets

The potential for bagasse in Indonesia is 30 tonnes / Ha / year. Meanwhile, the area of sugarcane (2014) covering an area of 447,000Ha [63.46% is in Java, the remaining 36.54% is outside Java], the total potential for bagasse is around 13.41 million tonnes / year, the planting area has decreased by 6%. compared to 2013, (470.198Ha). Therefore, in order to meet domestic sugar needs and reduce imports of raw sugar, the Government has prepared an additional 500,000 Ha of sugar cane land in Southeast Sulawesi, P. Aru and Merauke, as well as building 10 new domestic sugar factories. In the future, there will be an additional 15 million tons / year of bagasse. Other sugarcane solid waste that comes from filtering the sap on the rotary drum filter is called blotong. When dried, blotong can be directly used as fuel in the kitchen for cooking. Blotong is generally used for compost.

Site Selection and Budget for Bagas Pellet Factory

The bagas factory site must be located in a location where raw materials are abundant, cheap and near the airport / port in order to facilitate product transportation, so that raw material costs and other costs (labor, warehouse rent, management fees, etc.) can be saved as low as possible. Aspects of building legality and industrial permits: TDI, SIUP, HO, IMB, etc. related need to be prepared. Certificates for export (SVLK) and product certificates (for example from Sucofindo, and SGS) are also prepared.

The initial investment for a bagasse pellet mill is around 112,414 USD with a capacity of 1 ton / hour (capacity can be increased to 6 tonnes / hour by adding required equipment). The factory building investment is around 19,271 USD with a floor area of ​​6,000m2. The initial capital investment of the equipment is around 72,266 USD including dryer 24,089 USD, stranding cage 1,927 USD, electric cabinet 1,927 USD, pellet machine (1tonnes / hour) 25,695 USD, etc. Working capital is around 40,148 USD for initial storage of raw materials and pre sale of products.

If the market and operations are stable, you can increase your investment. The dryer 24,089 USD can be used for 3 pellet factories, you just need to increase the investment in the Stranding cage, pellet machine and conveyor. If the pellet mill is more than three, a dryer needs to be added and a fork-lift truck is required. The cooling machine needs to be considered depending on the production situation.

Bagasse Pellets Cost & Profit Analysis

Business target: 500 tons / month (initial). When normal operation, the monthly production can be increased up to 1,500 tons or 3,000 tons. The annual product is about 30,000 tons.

Example of Estimated Costs and Profits of Bagasse & Sawdust Pellets in Brazil

ROI of Bagasse Pellets:

•        Sugarcane bagasse raw material price: 19.45 USD / ton

•        Transportation costs: 3.24 USD / ton [packing and exit costs]

•        Crumbling: 0

•        Dryer electric load: 1.39 USD / ton [7.5kV electric machine drying 0.7 ton / h]

•        Electricity pelletizing load: 11.67 USD / ton [90kW 1 ton / h pellet power machine]

•        Packing: 5.19 USD / ton [25kg / sack; 0.13 USD / sack]

•        Direct labor: 8.10 USD / tonne [1 tool for 8 workers, 11.34 USD for 1 worker per day]

•        Site costs: 5.33 USD / tonne [19,434 USD for 10 years use]

•        Equipment costs: 3.25 USD / ton [80,976 USD tools for 26 days / month within 5 days of use]

•        Maintenance costs: 4.86 USD / tonne [cost of dies / blades worn]

•        TOTAL cost: 62.48 USD / ton

Profit Calculation: Total costs: 62.48 USD / tonne; selling price of pellets at the factory: 97.17 USD / ton; net profit for one tonne was 34.69 USD. If the monthly production is 500 tons, the monthly net profit is 17,345 USD.

Meanwhile, ROI of Sawdust Pellets:

•        Raw material price of sawdust: 22.67 USD / ton

•        Transportation costs: 4.86 USD / ton [packing and exit costs]

•        Crumbling: 0

•        Dryer electric load: 2.08 USD / ton [7.5kV electric machine drying 0.7 ton / h]

•        Pelletizing power load: 15.16 USD / ton [90kW 1 ton / h pellet machine]

•        Packing: 5.18 USD / ton [25kg / sack; 0.13 USD / sack]

•        Direct labor: 8.10 USD / tonne [1 tool for 8 workers, 11.34 USD for 1 worker per day]

•        Site costs: 5.33 USD / tonne [19,434 USD for 10 years use]

•        Equipment costs: 3.25 USD / ton [80,976 USD tools for 26 days / month within 5 days of use]

•        Maintenance costs: 5.83 USD / ton [cost of dies / edges of felt]

•        TOTAL cost: 72.46 USD / ton

Profit Calculation: Total costs: 72.46 USD / ton; selling price of pellets in factory: 137.65 USD / ton; the net profit for one ton is 65.19 USD. If the monthly production is 500 tons, the monthly net profit is 32,595 USD.

Posted in: