Date : 21st April 2011

Venue : PNB Darby Park, KL

PRESENTATION STRUCTURE

• FRIM

• Paper Mill Sludge Pellet

• Drum Method for Carbonization

• Rice Straw Pellet System

• HTD for Rubberwood and Tropical Hardwood

• Conclusion

FRIM

• Established 1929

• Statutory body

• Malaysia Forestry Research and Development Board under the Ministry of

Primary Industries in 1985 (Act 319)

• In 2004, moved to Ministry of Natural Resources and Environment

• Carry out R, D & C across the forestry

value-chain

FRIM

• Five research divisions:

• Forestry

• Product Development

• Biotechnology

• Natural Products

• Conservation of Forest Biodiversity

• With 5 other supporting divisions.

Vision & Mission

• Vision

To make FRIM a world-class tropical

forest research institute

• Mission

To achieve excellence in scientific

research, development and forestry services

Pellets from Paper Mill Sludge

INTRODUCTION

•Malaysia,

• 1 million metric tonnes of sludge generated

• Innovation

• Industrial Sludge Fuel Pellets

• Recycling Industrial fiber wastes into briquettes

• Environmentally Friendly Product can be widely used in industry – boiler feedstock

PELLETS FROM PAPER MILL SLUDGE

THE INNOVATION

•Producing Pellets from sludge ----� Environmentally friendly method of disposing sludge

•Pellets = converting loose material (saw dust) into a compact shape sans binder through compression

•Creates a new opportunity for the paper industries

PELLETS FROM PAPER MILL SLUDGE

• Penggunaan 100% bahan enap cemar kertas

• Pembuatan produk pellet yang di hasilkan kepada saiz yang diperlukan.

• Produk alternatif kepada kayu sebagai bahan

bakar• Mengeksploitasi penggunaan bahan enap cemar

yang terhasil sebagai bahan produk nilai tambah.

UniquenessBahan enap cemar

Proses pengeringan

EC pellet

Campuran

Proses pemampatan

Flow Chart EC PelletEC 70:30 50:50

Kandungan lembapan (%) 7.5 4.0 4.3

Ketumpatan (kg/m3) 150 1223 1176

Bahan meruap (%) 52.1 67.4 62.9

Kandungan abu (%) 40.1 21.8 16.5

Kandungan karbon (%) 7.8 10.8 20.6

Kandungan kalori (MJ/kg) 5.2 11.7 13.1

• Bersih dan mudah dikendalikan• Mempunyai ketumpatan yang lebih tinggi

• Mempunyai bentuk dan saiz yang seragam• Meningkatkan lebih daripada 10 isipadu sisa• Tempoh penyimpanan lebih lama

• Pembakaran yang sekata dan lengkap • Membuka peluang yang menguntungkan kepada

industri kertas yang menghadapi masalah

pelupusan bahan enap cemar.• Kaedah pelupusan yang mesra alam.

Advantages

Drum Method for Carbonization• Charcoal is a carbonaceous solid with a fixed

carbon content of 70% or more• The drum method is suitable for the production of

coconut shell charcoal.

• The major drawback is the emission of large quantity of smoke and tar during carbonisation process which makes it environmentally

hazardous• The other problems pertained to the quality and

uniformity of the charcoal produced

Introduction

Innovation

• Charcoal in a Simple, Quick, Efficient, and

Economic kiln. • reduce emissions and its greenhouse effect.• It also and can be constructed in a suitable sizes

by local materials. • Environmentally friendly, productive and

economical for charcoal production in Malaysia

• Clean and easier handling• Complete carbonisation• Efficient – quality & quantity

• Low cost• Environmental friendly

Advantages

Comparison

EFDM Drum

Carbonisation (hours) 22 24

Charcoal (kg) 32 18

Efficiency (%) 40 20

Cost (RM) 60 50

Moisture content (%) 6.1 12.5

Volatile matter (%) 12.4 21.0

Ash content (%) 2.3 2.5

Fixed carbon (%) 85.3 76.5

Calorific value (MJ/kg) 32.7 31.0

Products

Rice Straw Pellet Introduction

• Rice straw is the dry stalks of rice plants, after

the grain and chaff have been removed. • More than 1 million tonnes of rice straw are

produced in Peninsular Malaysia annually.

• Burning in the open air is the common technique of disposal that contribute to air pollution.

Process

• Pellets are a type of solid fuel, generally made

from compacted residues. • Pellets are produced by compressing the

residues which has first passed through a crusher

to provide a uniform mass. • They are usually produced as a byproduct of

agricultural activities.

• The pellets are extremely dense with low moisture content that allow them to be burned with very high combustion efficiency.

Properties

Straw Wood Oil palm

Moisture content (%) 7.5 7.5 5.9

Volatile matter (%) 71.3 82.8 88.2

Ash content (%) 12.8 1.2 4.2

Fixed carbon (%) 8.4 8.5 1.6

Density (kg/m3) 1060 1265 982

Calorific value (MJ/kg) 15.8 19.1 19.7

• Uniform in size and quality

• Easy to transport and store• The process increases the net calorific value of

material per unit volume

• The process often helps to solve the problem of residues disposal

• The process helps to reduce deforestation by

providing a substitute for fuel wood

Advantages

Process of EFB for Biodegradable Container

• Industry Sector

Eco-Products ;

Environmental Services

Introduction

• In Malaysia, food containers, industrial packaging and medical utensil are mostly made from plastic

either from polylactide (PLA) or polyethylene terephthalate (PTE).

• Products made from plastic are not environmentally friendly due to their difficulty in composting, and costly due to the escalating

price of petroleum.

• In developed countries, these products are made

from lignocelluloses fibres that are biodegradable.

Agricultural Residues

• Malaysia is blessed with abundant supply

of natural fibres.

• There are million of tones of agricultural residues that can be used as a raw

material to produce such moulded pulp packaging products.

• Moulded pulp packaging is made from pulp which is moulded into a shape designed to

hold and protect the products to be packed.

Oil Palm Biomass

• Oil palm biomass, the most abundant fibre resource, is readily available from existing oil palm plantations and palm oil mills.

• Each year, the oil palm industry generates approximately 13.9 million tonnes of moisture-free cellulosic materials to act as renewable and permanent feedstock raw material for the production of paper pulp.

• Thus, oil palm biomass that includes oil palm trunk (OPT), oil palm fronds (OPF) and empty fruit bunches (EFB) could become supplementary fibre sources of short-fibered pulps that traditionally has been produced from hardwoods.

FlowchartExamples of moulded products can be made by oil

palm biomass.

HTD System for Rubberwood and Tropical

Hardwood

32

DESCRIPTION OF THE TECHNOLOGY

Description of Product (s)

THE ESSENTIAL SYSTEM FEATURES CONSISTS OF,

• Main HTD Chambers built-up of proprietary K-Block panels- light weight with sufficient stiffness to limit deformation under high

temperature.

• The handling line is a platform trolley holding timber packs which are

forklift-loaded.

• A physical restraint protocol is also incorporated to ensure quality

throughput of lumber batches.

• The humidification system to provide both the steam spray and water

spray (at ambient temperature) which are essential stages of HTD protocol.

Con’t… Description of product

• Pneumatic control ventilation system.

• Industrial PLC (programmable logic controller)

instrumentation which coordinates the monitoring and

controlling of various parameters as specified by the HTD protocol

• Uniform cross-flow air circulation through timber stacks at high speed of 2.5 to 3.5 m/s

34

IBS HTD STRUCTURE

35

IBS HTD STRUCTUREProperties of HT-dried Rubberwood

Reduced warping in timber

Enhanced grain feature

Better dimensional stability

Slight increased in specific strength

Production Volume

• 14 ton per kiln per 1-day cycle

• 1,260 ton per month

• 15,120 ton per year

Standard and Regulation

• Compliance with EU Directives

– Categorisation of borates under “Reprotoxic Category 2”

under the Dangerous Substance Directive (67/548/EEC)

MANUFACTURING ASPECT

37

PROPOSED SELLING PRICE & MANUFACTURING COST

AND

COMPARISON WITH AVAILABLE PRODUCT IN THE MARKET

• Proposed Selling Price RM 1,430/t

• Manufacturing Cost RM 1,267/t

• Profit Margin RM 163/t

Custom HT-Drying Service Charges

• Proposed Service Charges about RM 300/t

Customised HTD System Package

• Proposed Selling Price RM 5-6 million per package

39

MARKET POTENTIAL

Current Drying Practice in Malaysia

95% 5%

Conventional

System

(Temp < 80 degC)

Others

WHAT ARE THE MARKET SIZE – LOCAL & INTERNATIONAL

Targeted replacing 40% of existing conventional system in Malaysia

125 (51%)74 (30%)

47 (19%)

Kiln Drying Plants in MalaysiaPeninsular MalaysiaSabah

Sarawak

Midterm, TWI will explore the export market in the Asia Pacific Regionespecially Indonesia, Vietnam, India and China.

Source: MTIB

Some of the much improved attributes arisen from FRIM innovation are,

� Reduced negative impact on the environmentHTD system offers an alternative solution to use of chemical preservative

borates via use of high-heat treatment technique.

� Energy-efficient systemThe HTD time for 30 mm-thick sawn dimension stocks is reduced to

about 2 days compared to conventional drying which requires 14-16 days.

� Cost-efficient operationA techno-economic study shows that a complete HTD plant can be set

up with a capital investment comparatively less than that required for

setting up a conventional drying plant. The comparisons are based on the same overall production capacity, designed for both types of kiln

system.

n WHAT IS THE ADVANTAGE/DISADVANTAGE

�Enhanced timber quality• Minimise warping via a physical restraint protocol to maintain a

straight-form sawn timber.

• Enhanced wood grain feature and a more uniform albeit darker colour throughout the lumber.

• Increased dimensional stability - has lower equilibrium moisture content (EMC), less movement (shrink and swell due to

fluctuating ambient moisture) under general service condition.

PHOTO OF THE PROTOTYPE

HTD SYSTEM

Products produced from HT-dried rubberwood

CONCLUSIONCONCLUSION

� Environmentally friendly

� Cost-effective

� Just in time (JIT) stock holding

� Energy efficient

� Enhanced timber quality

� HTD the solution to chemical free rubberwood

� Ensures Malaysia’s continued dominance in the

rubberwood industries.

Bil Researcher Division Title of Invention

1 Puad Elham Forest Products Versatile Charcoal Briquette Machine

2 Mohd Nor Mahat Forestry Biotechnology Torrified Acacia Wood As Bio-Coal (FRIM TRAW)

3 Abdul Rashid LiNatural Resources

Products

Pectin-Rich fraction of Morinda Citrifolia as

glucose lowering agent

4 Dr Rushdan Ibrahim Forest ProductsConverting oil palm empty bunches into all types

of alkaline pulps for different types of paper

5Dr Nor Azah Mohamad

AliNatural Products

Natural based essential oil product with potential

adulticidal effects

6Mohd Shahidan Mohd

ArshadNatural Products

Standardised Tinospora Extract (Tinosporex™)

with anti-hypercholestrolemic property

7Dr Mohd Khairun

Anwar UyupNatural Products Phenolic-Treated Plybamboo (PTP)

8 Dr Nor Hasnida Hassan Forestry BiotechnologyInduction of hairy root culture from Tongkat Ali

explants using Agrobacterium rhizogenes

Bil Researcher Division Title of Invention

9 Dr Nor Hasnida Hassan Forestry BiotechnologyProduction of Tongkat Ali bioactive

compounds from hairy root culture

10 Dr Hasnida Hassan Forestry BiotechnologyMicropropagation of Tongkat Ali using

tissue culture techniques

11 Dr Hasnida Hassan Forestry Biotechnology

In vitro propagation of Aquilaria hirta

(Chandan) using tissue culture

techniques

12 Dr Hasnida Hassan Forestry BiotechnologyMicropropagation protocol of Mas

Cotek (Ficus deltoidea)

13Dr Wan Tarmeze Wan

AriffinForestry Biotechnology

Bamboo-Oil Palm hybrid Engineered

Lumber (B-POPS™)

14 Dr Hasnida Hassan Forestry Biotechnology

In vitro propagation of Aquilaria

malaccensis (Karas) using tissue culture

techniques

15Dr. Wan Tarmeze Wan

AriffinForestry Biotechnology

Enginneered lumber from crushed and

dismantaled bamboo material

16 Dr. Mohd. Ilham Adenan Forest Biodiversity

ECfC 06: a standardized extract of

Erythroxylum cuneatum forma

cuneatum (Miq.) Kurz (cinta mula) as

herbal remedies for addition therapy.