Enhancing Sustainability In Tobacco

Production : Energy Efficient Curing

Barn Development For Smallholder

Growers In Zimbabwe

CORESTA CONGRESS 2016, BERLIN.

Wisdom Munanga TOBACCO RESEARCH BOARD

KUTSAGA

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PRESENTATION OUTLINE

• Barns and Curing fuel – Zimbabwean Situation

• The shift in the grower base – associated challenges

• The Alternatives (Alternative fuels, Adoption of

new barn designs)

• Energy efficient barn (the design, efficiency tests)

• Discussion and conclusion

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• Zimbabwe has for decades

been known as the source of

some of the world's finest

flavour tobacco.

• Pre-2000, 80% of the crop

grown by large scale

commercial growers.

BACKGROUND

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• The crop

predominantly

cured using coal as a fuel source.

• Growers had a

wide range of barn options.

BACKGROUND

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THE BARN TYPES : CONVENTIONAL

• ~2 – 3 ha

capacity

• 2 – 2.5 kg of

coal per kg of

cured

tobacco

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THE BARN TYPES : CASCADE

• ~14 ha

capacity

• 1.5 – 2 kg

of coal per

kg of

cured

tobacco

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BARNS : BULK CURERS

• ~3 ha capacity

• ~ 2 kg of coal

per kg of cured

tobacco

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THE BARN TYPES : TUNNEL BARN

upto 120 ha capacity

0.9 – 1kg of coal per

kg of cured tobacco

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THE BARN TYPES : TUNNEL BARN

upto 120 ha capacity

0.9 – 1kg of coal per

kg of cured tobacco

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But change is inevitable…. • In 2003 – grower base

changes

• 85% of crop grown by

small scale growers.

• On 1-2 ha per individual

• Mostly dependent on wood for curing (coal

expensive, not on electricity grid)

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CONSEQUENCIES - LOSS OF INDEGINOUS TREES

• Indigenous trees used

as fuel sources

• However, barns

designed for coal

• Inefficient, with SFC of

as high as14 kg.

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EXTENT OF DEFORESTATION IN ZIMBABWE

The indigenous msasa tree or

zebrawood

(Brachystegia_spiciformis)

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EXTEND OF DEFORESTATION IN ZIMBABWE

The indigenous msasa tree or

zebrawood

(Brachystegia_spiciformis)

2008 Pfura district, Mt

Darwin, Zimbabwe

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EXTEND OF DEFORESTATION IN ZIMBABWE

The indigenous msasa tree or

zebrawood

(Brachystegia_spiciformis)

2008 Pfura district, Mt

Darwin, Zimbabwe

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DEFORESTATION IN ZIMBABWE....

1. Expansion of agricultural land,

2. Land clearing for resettlement

3. Tobacco curing (15%)

4. Energy provisions (household energy

consumption based on woodfuel)

5. Veld fires

6. Other (curing of bricks, construction poles)

Zim- Forestry Commission

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DEFORESTATION IN ZIMBABWE....

1. Expansion of agricultural land,

2. Land clearing for resettlement

3. Tobacco curing (15%)

4. Energy provisions (household energy

consumption based on woodfuel)

5. Veld fires

6. Other (curing of bricks, construction poles)

Zim- Forestry Commission

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DEFORESTATION IN ZIMBABWE....

1. Expansion of agricultural land,

2. Land clearing for resettlement

3. Tobacco curing (15%)

4. Energy provisions (household energy

consumption based on woodfuel)

5. Veld fires

6. Other (curing of bricks, construction poles)

Zim- Forestry Commission

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DEFORESTATION IN ZIMBABWE....

1. Expansion of agricultural land,

2. Land clearing for resettlement

3. Tobacco curing (15%)

4. Energy provisions (household energy

consumption based on woodfuel)

5. Veld fires

6. Other (curing of bricks, construction poles)

Zim- Forestry Commission

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DEFORESTATION IN ZIMBABWE....

1. Expansion of agricultural land,

2. Land clearing for resettlement

3. Tobacco curing (15%)

4. Energy provisions (household energy

consumption based on woodfuel)

5. Veld fires

6. Other (curing of bricks, construction poles)

• 300,000 ha of woodlands

lost annually - Forestry

Commission

• 15% of deforestation rate

- tobacco curing.

Zim- Forestry Commission

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So, What is the tobacco

industry doing about their

contribution?

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ZIMBABWEAN TOBACCO INDUSTRY INTERVENTIONS

Three pronged approach

1. Promoting woodlot

establishment by growers

2. Search for alternative

fuels

3. Energy efficient curing

systems

TRB INITIATIVES TOBACCO MERCHANTS

• Sustainable

Afforestation

Association (SAA)

– Formed (2013)

• Initiates

reafforestation

programmes

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1. Promote woodlot establishment

TRB INIATIVES IN DETAIL 2016

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TRB’S GOSIP – 3Ps

2010 - TRB initiates the

”Governance and Social

Investment Programme

for People, Planet and

Profit” - GOSIP-3Ps

programme

Eucalypt seedbed at

Kutsaga - 2016

TRB’S GOSIP-3PS

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TRB’S GOSIP – 3Ps

2010 - TRB initiates the

”Governance and Social

Investment Programme

for People, Planet and

Profit” - GOSIP-3Ps

programme

Eucalypt seedbed at

Kutsaga - 2016 Objective : Ensure responsible, sustainable &

viable tobacco production through

encouraging growers to;

• Nurture and manage indigenous forests

• Establish own woodlots

TRB’S GOSIP-3PS

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THE ACTIONS

• Provision of free

eucalyptus seed &/or

seedlings to growers

• Train growers on

eucalypt tree

production.

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• Seed worth 500 000 ha distributed & ~58 %

established (329/559)

• Seedlings - 3.5 million ha

equiv. Collected & ~40 % were planted

TRB PROGRESS TO DATE

Government introduces the Tobacco wood energy act in 2012

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INDUSTRY EFFORT - SAA

Sustainable Afforestation Association, a non

profit organization formed by the Tobacco

merchants in 2013.

Objectives : to provide a sustainable source of

timber for the tobacco industry &

to implement strategies to conserve & rejuvenate

indigenous & commercial forests

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SAA ACHIEVEMENTS TO DATE

• 8 000 ha of

eucalypt

plantations established

• Annually ~12 million trees (@

1600 plants/ha)

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SOME CHALLENGES…..

1. Veld fires

2. Pests and disease e.g.

blue gum wasp and the

red gum lerp psyllid

TRB /Forestry

Commission/ SAA -

working on biocontrol

options

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OTHER TREE ALTERNATIVES

• Bamboo

• Arcacia

• Msasa

Msasa tree seedlings @

Kutsaga

Bamboo trial @

TRB

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2. Alternative fuels

TRB INIATIVES IN DETAIL cntd 2016

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SOLAR

• 100 % solar curing

system was evaluated.

• Temperatures not more than 57 °C.

• Great potential as

hybrid system.

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COAL BRIQUETTES

• Made from coal dust.

• Can burn unassisted with

forced air.

• Curing tests indicated a

SFC of 4 kg @ CE of 75%.

• This was recommended.

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BIOGAS

• Can be produced on the

farm.

• Curing tests were

conducted.

• Recommended in a

hybrid system.

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ETHANOL

• Production at ~ 300 000

L/day

• Curing tests indicate SFC of

2-3 L.

• Pursuing cost reduction &

heat exchanger efficiency.

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3. Energy efficient barns

TRB INIATIVES IN DETAIL cntd

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THE ROCKET BARN

• 2011 - extensive research to

modify rocket for Zim conditions.

• Modified barn - fuel efficient (SFC

of 4 kg).

• Adopted and widely used by most

small scale growers.

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THE ROCKET BARN

• 2011 - extensive research to

modify rocket for Zim conditions.

• Modified barn - fuel efficient (SFC

of 4 kg).

• Adopted and widely used by most

small scale growers.

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ROCKET BARN : LIMITATIONS

• Low capacity (max. 15 000

leaves)

• High cost of some

components e.g. the

double chimney

Hence the need for bigger

capacity but low cost barn

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KUTSAGA COUNTER CURRENT

1 (KCC1) BARN DEVELOPED

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Roof IBR sheet Light weight and affordable

Design feature Description Comments

Furnace V-slot and in protruding inside the

barn Efficient fuel-air mixing

Heat exchanger Brick firebox channel with metal

top surface

Stable temperature

Walls Farm brick, double wall Low cost

Exhaust chimney Brick channel, built inside the barn Exhaust heat retention

Ceiling Thatch grass insulation

Capacity 1200 clips (45 000 leaves) Economically suitable for

small scale growers

KUTSAGA COUNTER CURRENT 1 SPECIFICATIONS

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• Uses a counter-current

airflow principle IE

• the 2 fluids involved in

heat exchange flow in

opposite directions.

• More efficient heat exchange system.

KCC1 – THE PRINCIPLE

KCC1 barn @ Kutsaga

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• Uses a counter-current

airflow principle IE

• the 2 fluids involved in

heat exchange flow in

opposite directions.

• More efficient heat exchange system.

KCC1 – THE PRINCIPLE

KCC1 barn @ Kutsaga

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BARN DESCRIPTION

Rocket 1 (R1) Brick firebox with double metal chimney

Rocket 4 (R4) Brick firebox with double metal chimney

Conventional 1 (control) Flue pipe system and brick chimney outside the barn

KCC1 barn (test) Brick double firebox with brick chimney inside barn

KCC1 EFFICIENCY EVALUATION TEST

The treatments

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1. Quantity of leaf loaded into barn

2. Duration of each curing stage recorded

3. Cured leaf quality (TRB’s Grade Index)

4. Specific Fuel Consumption (SFC) - (wood

mass : leaf mass)

MEASUREMENTS

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DATA ANALYSIS

• The trial was repeated six times

• Data tested for normality of residuals and

homogeneity of error variance

• Subjected to analysis of variance (ANOVA)

using GENSTAT statistical analysis package,

17th edition.

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RESULTS AND DISCUSSION

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BARN CAPACITY

Rocket 1 (R1) 0.5 ha

Rocket 4 (R4) 0.6 ha

Conventional 1 0.8 ha

KCC1 barn 1.5 ha

QUANTITY OF LEAF LOADED INTO BARN

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1. TIME TAKEN TO COMPLETE CURING

• In the end, all barns took

similar time taken to

complete the curing cycle

(7 days).

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1. TIME TAKEN TO COMPLETE CURING

• In the end, all barns took

similar time taken to

complete the curing cycle

(7 days).

BARN FUEL CONVERSION EFFICIENCY

7.22

11.6 10.5

23.99

0

5

10

15

20

25

30

Conv 1(Standard) Rocket (R1) Rocket (R4) KCC1 (Test barn)

Fu

el C

on

ve

rsio

n E

ffic

ien

cy

(%

)

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2. LEAF QUALITY - GRADE INDEX (%)

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3. SPECIFIC FUEL CONSUMPTION (SFC)

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SUMMARY & CONCLUSION

1. KCC1 Barn had a higher capacity – 1.5 ha

2. Recorded the lowest SFC

3. Leaf quality and turn around time

maintained

4. Use of energy efficient barns (Rocket &

KCC1) and own curing fuel or alternative

fuels – can curb deforestation

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OVERAL SUMMARY

Zimbabwe ensuring sustainability in tobacco

production through;

• Re - afforestation programmes (TRB/SAA)

• Research on alternative curing fuel sources

• Research in energy efficient curing systems

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CONCLUSIONS

Growers have continually

been provided with tools that

ensure that the Zimbabwean

crop is grown in a sustainable

and responsible manner

Eucalypt wood

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THANK YOU!!

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ACKNOWLEDGEMENTS

1. TRB Management and Staff 2. CORESTA 2016

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