Benefits of Onsite Energy Production for Cotton Gins

As cotton acreage and the number of operating cotton gins continues to decline in the mid-south region of the cotton belt, cotton processing costs must be minimized and returns optimized to maintain viability in the industry. Proposed regulations for greenhouse gas emissions at power plants are cause for concern that electricity costs may increase significantly in the near future. By utilizing a thermal conversion system to generate power onsite, cotton gins can provide adequate electricity and heating capabilities to become self sufficient and independent of the strains that traditional power sources can present. A conversion system has been developed that consists of a fluidized bed gasifier that converts cotton gin trash to a low calorific value (LCV) gas and a staged combustion system that converts the gas into electric power and heat. As opposed to energy produced from fossil fuels, power produced by a renewable biomass like cotton gin trash is considered carbon neutral energy production. Essentially, all of the carbon dioxide produced in the conversion of gin trash to a useable energy does not create a net increase in greenhouse gases (GHG) in the atmosphere. Also, the char produced by the gasification process is in the form of activated carbon that may have value for a number of industrial applications. This paper describes the concept for sizing and integrating the proposed power plant into an existing cotton gin, systems analysis of cost savings on electricity and heating gases, and analysis of the logistic principles for storing the gin trash and feeding the power plant. Potential markets and commercial demand for the activated charcoal and excess electricity produced will be evaluated. Self sufficient onsite production of energy products may allow gins to stay open and remain profitable in the event that electricity or heating gases become economically infeasible for use.