INTEGRATED RECOVERY AND REGENERATION … Dr. Wendy Ng, Regional...INTEGRATED RECOVERY AND REGENERATION SYSTEM ... o own operating palm oil mill, ... o Integrated Waste Recovery and

INTEGRATED RECOVERY AND REGENERATION SYSTEM (REGEN SYSTEM)

THE FUTURE OF PALM INDUSTRY

WENDY NG, PhD Eureka Synergy Sdn. Bhd.

20 August 2015 REGEN - 2 PALMEX THAILAND

Introduction of Eureka Synergy

o Eureka Synergy is founded in 2011.

o Our team haso continuous research & development activities on palm

biomass processing technology since 2005o continuous research & development activities with

renown institutionso own operating palm oil mill, plantation and biomass

processing plants

o Integrated Waste Recovery and RegenerationSystem (REGEN System) for palm industry

Eureka Synergy Sdn Bhd www.eureka-synergy.com

PT Bio Plantmate Indonesia www.bioplanmate.com

The University of Nottingham Malaysia Campus www.nottingham.edu.my

Crops for the Future Research Centre www.cropsforthefuture.org

Research Partners / Collaborators 3



Outline of Presentation

o Introduction of Palm Oil Industry

o Palm-based Biomass

o Integrated Waste Recovery and RegenerationSystem (REGEN System).

o Development of Palm Industry

Palm Industry



STERILISATION PROCESS

EXTRACTION PROCESS

PURIFICATION PROCESS

TRESHING PROCESS

RECEIVING UNIT

STORAGE UNIT

Crude palm oil

Fresh fruit bunch

Empty fruit bunch

Palm fresh fruit bunch from plantation

Palm kernel cake

Sterilised fruit bunch

Sterilised fruit

Sludge and oil

Sludge

Palm kernel CRUSHING PROCESS

EXTRACTION PROCESS

Palm kernel oil

STORAGE UNIT

Palm kernel shell

Crude palm oil to market

Palm kernel oil to market

TYPICAL PALM OIL MILLING PROCESSBlue wording

- Intermediate product

Red wording - Waste / Biomass

Mesocarp fiber

+ POME

(wastewater)

Agricultural Residues

o Abundant > 10 million tonnes (dry) annually – palm biomass

o Main contributor of biomass in palm oil industry Palm oil mill

- Empty fruit bunch (EFB) - Palm oil mill effluent (POME) - Mesocarp fibre - Palm kernel shell - Palm kernel cake

Ligno-cellulosic materials


Calculation: Based on 2009 data derived from MPOB’s Malaysian Oil Palm Statistics 2009 and MPOB calculation methodologies

Potential Availability Palm Biomass

Oil palm plantation area 675,000 million hectares

Thailand palm haversted area 675,000 ha (in 2014)

Source: USDA Foreign Agricultural Services (June 2015)

Estimated biomass 11.12 million tonnes (dry)

Estimated oil palm fronds

6.45 million tonnes (dry)

Estimated empty fruit bunch 1.00 million tonnes

(dry)

Estimated oil palm trunks

2.01 million tonnes (dry)

Estimated oil palm fiber and

oil palm shell 1.66 million tonnes

(dry)


• Generates high amount of palm biomass – Empty Fruit Bunches (EFB) – Palm Kernel Shells (PKS) – Decanter Cake (DC) – Palm Mesocarp Fibers (PMF) – Palm Oil Mill Effluent (POME)

Palm Oil Mill


o Empty Fruit Bunches (EFB)– Too many and not able to process all of them– Trade with low price

o Palm Kernel Shells (PKS)– Most of them consumed by biomass boiler for power

generation– Trade to local and oversea market

Current Scenario Waste Management System


o Palm Mesocarp Fibers (PMF)– Use for power generation in biomass boiler

o Palm Oil Mill Effluent (POME)– Generate high amount of POME– Not able to meet the safe discharge standard steadily– Not able to recover/recycle– Use for biogas generation

Current Scenario Waste Management System


o Huge amount of palm-based biomass– Potential source of energy and value added

products– Untapped energy sources

o Single technology (anaerobic digestion,compositing plant, pelleting system, etc.) does notsolve all problems

Remarks


The Evolution of Palm Industry


General Perception from Public


Evolution of Palm Industry


REGEN System Integrated Recovery and Regeneration System


Process Flow Diagram

Animal Feed Plant

Power Generation System

Biogas System Water Polishing

System POME

Biogas

Clear Water

Power

Pellet Production

Power

Fiberizing System

Composting System

Power

EFB

Short fibre

Decanter Cake

Boiler Ash

Power to Grid

Dried Long Fibre

Pellet

Organic Fertilizer

Fortified Fertilizer

Animal Feed

Fibre Mat System

Fibre Mat

Integration of Technologies

o Waste reduction

o Resource

sustainability o Optimal

processes

o Energy conservation

o Additional income



Eureka Synergy Sdn Bhd – Shortlisted by Institution of Chemical Engineers 1. Sustainable Technology Award 2015 2. Palm Oil Industry Award 2015

REGEN System Integrated Recovery and Regeneration System


Selection of technology is important...


EFFICIENCY ECONOMIC SUSTAINABILITY

o Palm oil mill capacity 45 ton/h = 2 MW o Palm oil mill capacity 60 ton/h = 3 MW

o Biogas -> power generation o Clear water -> process / daily consumption

Biogas & Water Recycling System


Power Generation System

o Biogas -> power generation o Feed-in tariff / Own consumption


Wastewater before treatment

After treatment Water quality during treatment

POME Treatment

POME to

Clear Water Quality


Fiberizing System


Fiberizing System


Commercial usage - Mattress manufacturing - Eco-mat manufacturing Prevent soil erosion Moisture retention and slow release of nutrient

Fiber specification - Moisture content 11-15 % - Length 5-15 cm - Container 19-21 mt / 40’HQ

Fiber-Mat System

CONTROL WEED

PROTECTIVE LAYER OPTIMAL WATER AND NUTRIENT ABSORPTION

REDUCE LABOUR

STABILIZE SOIL

RETAIN MOISTURE

100 % Natural Fibre

Permeable Surface Chemical Free

Biodegradable

Adjustable Density / Thickness


Pelletizing System

Pellet as ‘Bio-Fuel’


Pelletizing System Eco-culture Technology

Fish Pellet as ‘Fish Feed’


Composting System

Living Organic Fertilizer Fortified Fertilizer (Organic Based Fertilizer)

Total NPK > 5.5 % 5-5-10-2-TE 12-10-17-2-TE

customised

Organic matter > 35 % > 20 %

Moisture content < 25 % < 20 %

pH 8 - 9


Composting System


Composting System

Chemical Fertilizer ᐯ

Organic Fertilizer ᐯ

Fortified Fertilizer ᐯ

Fertilizer with Medication Effect Prevent / Cure Palm Ganoderma Disease


Fortified Fertilizer

Fortified Fertilizer Chemical Fertilizer

10 % N + 10 % P + 10 % K +

Trace Elements +

Biochar +

Organic Matter

10 % N + 10 % P + 10 % K +

Clay Improve nutrient uphold

Soil conditioner

Prevent nutrient deficiency

Deteriorate soil structure

Cost Effective Expensive as Compared to Organic Based Fertilizer

Imported Fluctuate Pricing

Less Sustainable

~70 %

A comparison with chemical fertilizer


Eureka Fertilizer Fertilizer that is able to prevent / cure Palm Ganoderma disease

o Our Research and Development Team - Industry Practitioner - Researchers (renown university) o R&D Progress - Fertilizer Formulation - Field trial


Other Uses of Palm Waste Fertilizer from palm biomass


Fertilizer to be returned to palm plantation o (close cycle)

Fertilizer to use in other industry

Chemical Fertilizer Organic Fertilizer

Observation: Difference in growth rate – number of leaves

Organic Fertilizer Trial

35


Organic Fertilizer Application on Melon Plant

Organic Fertilizer Control

36


Organic fertilizer utilisation on banana and date palm crop in Kesultanan Oman

Organic Fertilizer Application on Other Plants 37


MR 219 rice variety in Malaysia which yielded 10 ton/ha

A rice plant in its reproductive (flowering) stage fertilized with organic fertilizer

The CHRV, RC 174H or Mestiso 12 at maturity stage. The yield hits 7-8 ton and 9-10 ton during wet and

dry seasons, respectively

38

Organic Fertilizer Application in Paddy Cultivation

Organic Fertilizer Other Fertilizer

Organic Fertilizer Application on Tobacco Plant 39


When we have technology, here it comes quality control…


Incentives and Fines Quality & Quantity

o National & International Standards

o RSPO o BioNexus / BioEconomy Transformation Programme o Etc.


The promotion of the industry...


Incentives and Fines Governmental Initiative

o Feed-in tariff o Fines o Environmental regulations o Incentives


Incentives and Fines Joint-Venture Initiative

o Investor funds the investment o Capital-free with BOT and buy-back policy

SAMPLE JV MODEL Composting System

Palm Oil Mill Investor

Capital cost √

Operation cost √

Raw material (biomass) √

Management √

Product buy-back √

Revenue √ √

Facility ownership Year c onwards Year a – Year b


Conclusions

Huge potential of palm biomass available for production of high value products - Capture RM 30 billion business opportunity

REGEN System one 60 t/h mill

- Covert all biomasses into value added products - Save > 13,000 ton of coal per year - Reduce > 1,500 ton CO2 emission per year


For continuous sustainability and

improved technology efficiency,

we need technologies…


Development of Palm Industry Research and Developments & Trends

Industry

Institution (Academic)

Industry + Institution

In-house research and development team

Research institution / Academician Mostly funded by government /

ministry

Practitioner + Academician Funded by government / ministry /

industrial fund


Category Technology Value Added Product

Physical Densification Palm briquette Palm pellet

Hybrid plywood MDF

Biological Anaerobic Digestion Biogas Fermentation Bioethanol

Biopolymer Compost

Thermochemical Gasification Syngas Pyrolysis Bio-oil

Torrefaction Torrecfied biomass Liquefaction Bio-oil

Development of Palm Industry Recent research on palm oil-based biomass utilisation


Other Uses of Palm Waste Research and Developments & Trends

Mushroom Cultivation

Pot and Container

Paper Product


Thank You

Contact 1: Contact 2: Dr. Wendy Ng Dr. David Lim Tel. +6 016 821 8012 Tel. +6 019 217 7798 Email <[email protected]> Email <[email protected]> Website <www.eureka-synergy.com> Website <www.eureka-synergy.com>


Documents

INTEGRATED RECOVERY AND REGENERATION … Dr. Wendy Ng, Regional...INTEGRATED RECOVERY AND REGENERATION SYSTEM ... o own operating palm oil mill, ... o Integrated Waste Recovery and