SECOND GENERATION BIOFUELS FROM OIL PALM BIOMASS
Transcript of SECOND GENERATION BIOFUELS FROM OIL PALM BIOMASS
SECOND GENERATION BIOFUELS FROM OIL PALM BIOMASS
Loh Soh Kheang and Choo Yuen May
Malaysian Palm Oil Board (MPOB)
18th International Oil Palm Conference 22-25 September 2015 Cartagena, Colombia
PRESENTATION OUTLINE Introduction
Global Development Development in Malaysia
Oil Palm Biomass Availability, Energy Characteristics, Application
Palm Lignocellulosic-Based Second Generation Biofuels R,D & C Status, Conversion Efficiency & Potential Energy Outputs
Way Forward Conclusion
Biomass to Liquid: Bioethanol Company/
Location Technology Feedstock Production
capacity (MGY)
Project/plant Cost
(USD, mil)
Status
Beta Renewables - Novazyme – Inbicon / Crescentino, Italy
Pre-treatment - high T & P, Integrated Enzymes & PROESA Eng. Tech.
Wheat straw, rice straw, baggase, corn stover, etc.
biomass used: 270,000 t/yr
13-20
= 50 mil L
13 MW electricity
$159 (project)
Operational, Oct 2013
Abengoa Bioenergy / Hugoton, Kansas, USA
Enzymatic - custom-made enzymes hydrolysis
Multicellulosic biomass, crop residue and plant fibres
Biomass used: 315,000t/yr biomass
25
20 MW electricity
$685 (plant) Construction expected to complete, Dec 2013
Inbicon - DONG Energy – Novozymes /Maabjerg, Denmark
Mechanical conditioning, hydrothermal pretreatment, and enzymatic hydrolysis.
Wheat straw (50 t/hr)
Pdt: ethanol, biogas, electricity, fertilizer, solid biofuel
13-20
$390 - $580 (plant)
Estimated completion, 2016
Status of Commercial Bio-ethanol Plant from Lignocellulosic Biomass
Biomass to Liquid: Bioethanol
Company/ Location
Technology Feedstock Production capacity (MGY)
Project/plant Cost
(USD, mil)
Status
Iogen - Raízen Energia / Piracicaba, São Paulo
Steam explosion - separate hydrolysis & advanced fermentation
bagasse & cane straw (fully integrated into the 1st gen ethanol )
~13 $100 (plant) Plant start-up, 4th Q 2014
Mascoma - Frontier Renewable - Valero Energy / Kinross, Michigan, USA
Consolidated bioprocessing -a “drop- in” genetically-modified yeasts
Wood pulp and chips 20 $232 (construction, commission and start-up)
Estimated completion, 2014/15
Mitsui (MES) – Inbicon/Dong– Teck Guan
hydro-thermal (steam) pretreatment and enzymatic hydrolysis
Oil palm EFB 1.25 t/day CAPEX: €10
Operational, 2013
Status of Commercial Biorefinery Plant from Lignocellulosic Biomass
Biomass to Liquid: Bio-oil Company/
Location Technology Feedstock Production
capacity (t/day) Project/plant
Cost (USD, mil)
Status
Dynamotive, Guelph, Ontario, Canada
Fast Pyrolysis
Fluidized Bed Reactor
Wood Chip
200 $8.8 Operational, 2007
BTG BioLiquids,
Hengelo, Netherlands
Flash pyrolysis *biorefinery”
Rotating Cone Reactor
Wood Residue 120
- Estimated completion, 2014
Envergent (UOP-Ensyn) - Industria e Innovazione, Tuscany, Italy
Rapid thermal processing technology (RTP)
Mixed pine forest residues & demolition wood
150 - Expected to complete, Dec 2013
Envergent (UOP-Ensyn) - Tolko Industries, Alberta, Canada
RTP Wood chip & residue
400
(22.5 MGY)
$14.3 Expected to complete, Dec 2014
Envergent (UOP-Ensyn) – Felda Sahabat, Sabah
RTP Palm and bagasse residues
400
150
132,000t/yr EFB
$82
$45
(capital cost)
??
Status of Commercial Bio-oil Plant from Lignocellulosic Biomass
Biomass to Solid Biofuel: Pellet
Company (Location)
Technology Feedstock Production capacity (t/hr)
Project/plant Cost
(RM, mil)
Status
Detik Aturan Sdn. Bhd. (Kuala Selangor, Selangor)
Ring die Empty fruit bunch (EFB)
6 RM1.5 – 2.0 / t palm pellet
(production cost)
Operational, Oct 2011
Felda Palm Industries Sdn. Bhd ( KKS Semenhu, Kota Tinggi)
Ring die EFB
4
(24,000 t/yr)
RM6.5 Completed 2011
In operation
QL Tawau Palm Pellet Sdn. Bhd. ( QL Palm Oil Mill 1, Tawau)
Flat Die EFB 4
( 25,000 t/yr)
RM12.5 (inclusive civil,
building, electrical and consultation)
Completed 2011
GGS-MPOB briquettes
Piston press EFB 1
(37,440t/yr)
< RM8 Completed 2010, not in operation
Status of Commercial Solid Biofuel Production Plant
POME
Shell
Fibre
EFB
Renewable Energy
Biomass Others
Palm Biomass
Wood MSW Rice
Sawmill Rice Husk
Hydro
Small Hydro
Solar
PV
Thermal
Renewable Energy (Biomass Potential in Malaysia)
Wind
Biogas
Energy Crops Jatropha
Algae
Golden Crop: Oil Palm
Palm Frond (Stem, Rachis & Leaves)
Oil Palm Fruit
Oil Palm Stem
Oil Palm Trunk
Oil Palm – Fresh Fruit Bunch
Basic Facts • Fruits per bunch: 1000 to 3000
• Bunch Weight: 15-25kg
• Fruit size: 5 cm
• Fruit shape: Oval
• Fruit Color: Yellowish Red
• Fruitlet weight: 10 gm
Empty fruit bunch, EFB
Anatomy of oil palm fruit
Mesocarp: Palm Oil (PO)
Shell
Kernel: Palm Kernel Oil (PKO)
Basic Facts • Kernel per fruit: 5-8% • Mesocarp per Fruit: 85-92% • Oil per mesocarp: 20-50% • Oil per bunch: 23-25%
Palm shell
Mesocarp fiber
Oil Palm Biomass in 2014 No. Type of Oil Palm Biomass Amount (mil tonne)
Wet Weight Dry Weight
1. OPF (from pruning activity) OPF (from replanting activity)
- 42.06 3.03
22.5 (available)
2. OPT (replanting of 209,200 ha*) - 15.58
3. EFB (443 palm oil mills, FFB processed = 95.38 mil tonnes) = 22% x 95.38 mil tonnes
20.98 7.34
4. Mesocarp fibers, MF (13% ) 12.87 7.72
5. Palm kernel shells (6%) 5.24 4.46
TOTAL 80.19
6. POME generated from per tonne of FFB is about 65%.
63.90 (1789 mil m3 biogas)
3.18**
BIO-FERTILIZER
BIO-COMPOSITE & BIO-PRODUCTS
BIO-BASED CHEMICALS
RENEWABLE ENERGY
Heat and power* Solid, liquid and gas bio-fuels **
Mulch*
Compost*
MDF**, plywood*, fibremats*, bio-char** and activated carbon **
Sugars/Cellulose, ** lignin**, vitamin E**, carotenes**, squalene**
* Developed ** Emerging
Applications of Oil Palm Biomass
OIL PALM BIOMASS
Bioenergy Potential from Oil Palm Biomass (OPB)
BIOMASS TO GAS (BTG)
BIO-CHAR
BIO-OIL
BIOETHANOL
Production of bioethanol from EFB/OPT can be carried out via various different approaches—chemical, thermal and enzymatic processes.
Bio-oil from pyrolysis of OPB can be used for CHP, food flavoring, chemicals, heat and steam generation for small stationary engines, gas turbines and boilers.
Bio-char derived from pyrolysis or carbonisation process can be made into: i. solid fuel ii. oil /water slurries iii. activated carbon & soil enhancer.
SYNTHETIC DIESEL The synthetic diesel is obtained from Catalytic Depolymerazation Process (CDP) of OPB
T h e b i o g a s f r o m anaerobic digestion of POME can be used to fire b o i l e r s o r r u n g a s e n g i n e s t o p r o d u c e electricity.
BIOMASS TO LIQUID (BTL)
BIOMASS TO SOLID (BTS)
BIOGAS
BIO PRODUCER GAS
Quality bio-producer gas with higher heating value (HHV) can be produced via gasification using oil palm shell/fibre.
Briquetting of EFB fibre and palm shell can be conducted via piston press or screw extrusion technologies
BRIQUETTES/PELLETS
SYNTHETIC DIESEL
SECOND GEN. BIOFUELS – PALM LIGNOCELLULOSIC BIOMASS
COMBINED HEAT & POWER (CHP)
Long and Short EFB Fibers
Baled Solid Biofuels
• Cleaned EBF fibers (~10% mc), suitable for exports, mattresses filler and wood plastic composite.
• From the same process, the short fibres can be used for the production of pellets
• Shredded EFB fibers (~40% mc), suitable for bio-energy and bio-composite
SEGUNTOR BIOENERGY SDN. BHD. KINA BIOPOWER SDN. BHD.
Independent Biomass Cogeneration Power Plant
Electricity Generation from EFB – Grid Connected
Biomass to Solid (BTS) (Briquettes & Pellets)
Charcoal briquettes
Biomass Pellet Palm biomass briquettes – piston press technology
Torrefied Pellet
Palm Biomass Briquettes – Screw Extrusion Technology
Fibrous EFB & Bale
Characteristics: • Calorific Value 17895 – 18235 kJ/kg • Moisture content < 6.0% • Ash content < 6.0% • Specific Density 1100 – 1300 kg/m3
• Typical diameter sizes : briquettes Ø < 9cm, pellet Ø <1cm
Bioethanol Production from EFB
Inoculated with microbe Op7miza7on study
Treated Palm Biomass (Hydrolysate)
Fermenta7on in a bioreactor
Dis7lla7on at 75°C Mixture of fermenta7on product (bioethanol)
Pretreatment Hydrolysis Fermentation Separation Bioethanol
Bioethanol Produc7on from Oil Palm Trunk
Oil palm trunk sap extrac7on
Fermenta7on
Dis7lla7on
Purified bioethanol
Summary Bioethanol Production from EFB
• Bisulfite process and formiline pre-treatment (MPOB-Tsinghua-Shandong University)
• Optimised ethanol production from EFB: 6 dry tonnes of EFB can produce: 1 tonne of ethanol (17%), 0.8 tonne of high-purity lignin (14%) and 4.2 tonnes of hemicellulosic syrup (70%) as biochemical feedstock, of which 0.3 tonne of furfural can be produced (5%)
Bioethanol yield per t dry EFB = 15-25% Sugar conversion ~75% Fermentation efficiency ~ 85%
MPOB Pyrolysis Experimental Rig
Biomass to Liquid: Bio-oil Products: - Bio-oil (main), biochar & gas
Properties of bio-oil
Temperature (°C)
400 500 600
Calorific Value (MJ/kg)
20.23 21.41 21.17
Total Ash, % 0.49 0.65 0.37
pH 3.4 3.0 3.0
Moisture (%) 17.89 18.74 18.21
Density (g/cm3) 1.00 0.90 0.99 Biomass Experimental Kit (BEK)
Bio-oil: biofuel Biochar: Soil management/Carbon sequestration
Gasification of Palm Biomass Product: - Syngas
Other Gasification pilot plant Capacity: 30 kW, Fuel: EFB briquettes
• MPOB in-house technology – pilot scale down-draft fluidized sand bed gasifier
• Feed: EFB, palm shell and fiber
• Process optimization in progress to achieve: H2 (40%); CO (30%); CH4 (10%)
potential: 1-2 MW from 60 t/hr mill 282 MW (438 mills)
Mixing Anaerobic Aerobic
• Land application
• Composting
• Water course
POME
Cooling
Biogas / Methane
Cleaning Package Boiler / Biomass boiler
(cofiring)
Micro Turbine Electricity
Steam
Gas Engine
Flare
Electricity
Electricity
OPTIONS OF UTILIZATION
Diesel Engine (cofiring) Electricity
POTENTIAL BIOGAS UTILIZATIONS IN PALM OIL MILLS
Biogas capturing technology – cover lagoon and digester tank
Gas engine for electricity
Co-firing in biomass boiler
Composting / biofertilizer
Off-Site Utilization: Bio-CNG
BioCNG demo plant at Sg Tengi POM, Kuala Kubu Bahru, Selangor
Raw Biogas Pretreatment Compression CO2 removal Storage/
dispensing
MPOB-Ronser Zero Discharge POME Treatment System, POMTEC, Labu, Negeri Sembilan
Biogas Capture vs. Methane Avoidance
MPOB-BEE High Efficient Methane Fermentation System
POMEDfree Zero Waste Technology: 100% nutrients recycling
from POME, sludge, EFB via composting
Biogas Capture vs. Methane Avoidance
Source: Zulkifli et al., 2015
Biomass to higher value addition Starch HemicelluloseBiomass
FeedstocksCellulose Lignin Oil Protein
IntermediatePlatforms
Building Blocks
SynGas C2 C3 C4 C5 C6
H2, methanol & higheralcohols, oxo and iso-‐synthesis products, Fischer-‐Tropsch
chemicals
Glycerol, Lactic, 3-‐Hydroxypropionate, Malonic acid,
Serine
Succinic, fumaric& malic acids,
Aspartic acid, 3-‐Hydroxy
Butyrrolactone, Acetoin, Threonine
Itaconic acid, Furfural, Levulinicacid, Glutamic
acid, Xylonic acid, Xylitol/Arabitol
Citric/Acotonicacid, 5-‐Hydroxy methyl furfural, Lysine, Gluconicacid, Glucaric acid,
Sorbitol
SugarsGlucose, Fructose, Xylose
Arabinose, Lactose, Sucrose, Starch
BiobasedSyn gas
AromaticsGallic, Ferulic
acid, …
DirectPolymers &
Gums
• Fine chemicals, minor components, products mimic to petroleum counterparts, etc.
Way Forward – All-in-One Refinery
Conclusion
• Huge potential to fully utilise crop residues of the oil palm industry
• Successful efforts currently are mainly in energy and fertiliser applications
• It is a matter of time when the industry will move towards higher value applications with government support
• The oil palm industry is moving towards optimal value addition and zero waste
Malaysian Palm Oil Board (MPOB) Tel : 603-87694400 Fax : 603-89259446
MPOB website: www.mpob.gov.my Dr. Loh Soh Kheang: [email protected]