Palm oil residue waste potential and waste utilization … oil residue waste potential and waste utilization in Thailand ... palm oil mill increased 36%** 4. ... Decanter cake sludge:

Palm oil residue waste potential and waste utilization in Thailand

Mr.Krisada Chavananand

Chairman of Palm Oil Industry Club, Federation of Thai Industry (FTI) &

President, Thai Palm Oil Crushing Mill Association, Thailand

Clean Power Asia Conference & Expo 2013

29-30 April 2013

1

Contents

Background and General situation of Palm oil Industry

New challenging potential: Biomass to liquid?

Palm oil Production, Residue wastes, and existing energy production

Palm oil Residue waste potential and Waste Utilization

Existing POME & Biomass utilization: Power plant

RE potential: accruing amounts, utilization, cost/value, and distribution

Type and chemical characterization of palm oil residues

2

2006

FFB Production

(Ton FFB)

6,715,036

Production yield

(ton-FFB/Ha)

17.68 379,872

2007 6,389,983 14.99 426,120

Year Mature area

(Ha)

472,628

512,044

Plantation area

(Ha)

2008 9,270,510 20.09 461,555 588,175

2009 8,162,379 16.01 509,920 622,145

2011 9,880,000 16.44 600,758 685,600

Palm Oil Plantation and Production in Thailand, year 2006 - 2012

Remark: 1/ is an estimation value of year 2012 source: Ministry of Agriculture and Cooperative (MoAC), October 2012

2010 8,223,000 14.47 568,480 652,320

Background of Palm Oil Industry in Thailand

*** 80% of plantations in Thailand are small farmer. ***

2012 1/ 10,940,000 1/ 17.14 1/ 638,400 1/ 718,400 1/

3

Prachuapkirikhan – 4 Crushing Mills,

62.5 Tons/hr.

Krabi – 20 Crushing Mills, 740 Tons/hr.

Surathani – 19 Crushing Mills, 810 Tons/hr.

Chumphon – 21 Crushing Mills,

685 Tons/hr.

Satun – 5 Crushing Mills,

61.5 Tons/hr.

Trang – 4 Crushing Mills, 180 Tons/hr.

Songkha – 3 Crushing Mills,

17 Tons/hr.

Ranong – 1 Crushing Mill,

20 Tons/hr.

NakornSrithamarah – 2 Crushing Mills, 60 Tons/hr. Phang-nga – 1 Crushing Mills, 30 Tons/hr.

Nongkhai– 1 Crushing Mill

Palm Oil Crushing Mills, Year 2012

Chonburi – 2 Crushing Mills,

135 Tons/hr.

•Total 82 Crushing Mills •Total Production Capacity 2,801 Tons/hr

4

** From Year 2007 to 2012,Total palm oil mill increased 36%**

4

Palm Oil mill 17-18% CPO FFB

5-6% Kernel

Product Raw Material

EFB

Shell Waste water

Fiber d.cake

Losses

Oil loss

Kernel loss

Water

Electricity Steam

Diesel

Material Flow of Palm Oil Mill Production

5

WASTE

5-6%

Shell

Palm Oil Mills

Palm Oil Residues Waste

6

Palm oil industrial process and waste

Source of data: Clean Technology for the Crude Palm oil Industry in Thailand, Orathai Chavalparit, 2006

7

Existing Energy Production in palm oil mill

Biomass from palm

oil processes

Fiber

Exceed Biomass Residues

Palm Oil Processes

Palm oil mill capacity 60 t-FFB/hr

Steam to Palm oil mill

BOILER

Generator

Stack

Feed Water Pump

Steam Turbine

1.2 MW

POME

!! Efficiency Elec. of existing system ≤ 10%

8

Palm Oil Residue Waste Potential

Based on FFB production ~ 12.0 Million ton per year

POME Waste water Characteristic

COD

LHV

%CH4

~ 60,000 – 80,000 mg/L

21-23 MJ/m3 (depend on %CH4)

55 - 65%

Biomass Characteristic

EFB LHV = 7,240 kJ/kg @ 58.6%MC

D . cake

432 , 000 ton

Fiber

1 , 680 , 000 ton

EFB

2 , 640 , 000 ton

Shell

720 , 000 ton

Waste water

7 , 200 , 000 m 3

Fiber LHV = 10,730 kJ/kg @ ~37.2%MC

Shell LHV = 15,250 kJ/kg @ ~24%MC

9

Biomass Characteristic (EFB, Shell, Fiber)

Biomass Analysis

Proximate analysis Palm fibre Palm shell Palm bunch

EFB

Moisture, % 31.84 12.00 37.7

Ash, % 6.35 3.50 4.4

Volatile Matter, % 48.61 68.20 45.8

Fixed Carbon, % 13.2 16.30 12.1

Ultimate AnalysisCarbon, % 31.35 44.44 22.74

Hydrogen, % 4.57 5.01 2.27

Oxygen, % 25.63 34.70 28.78

Nitrogen, % 0.02 0.28 3.86

Sulfur, % 0.06 0.02 0.06

Chlorine, % 0.15 0.02 0.19

Ash, % 6.35 3.52 4.4

Moisture, % 31.84 12.00 37.7

Other Characteristics

Bulk Density, kg/m3 na na na

Higher heating value, kJ/kg 13,548 18,267 11,192

Lower heating value, kJ/kg 11,800 16,900 9,800

Source of data EFE Gulf Songkla

Biomass Ash analysisPalm fibre Palm shell Palm bunch

EFB

SiO2, Silica Dioxide, % 73.6 67.8 34.7

Al2O3, Aluminum Trioxide, % 2.43 14.6 1.2

Fe2O3, Iron Trioxide, % 2.72 1.6 1.8

CaO, Calcium Oxide, % 7.13 0.42 3.3

TiO2, Titanium Dioxide, % na na 0.1

MgO, Magnesium Oxide, % 3.24 2.9 2.9

SO3, Sulfur Trioxide, % 3.29 na 8

P2O5, Phosphate Pentoxide, % 2.26 1.8 2.5

Na2O, Sodium Oxide, % 0.93 0.26 0.8

Mn3O4, Manganese Oxide, % na na na

K2O, Potassium Oxide, % 3.86 9.6 40.1

Deformation Temperature, C 1170 1310 1080

Source of data EFE Gulf Kinoshita

na = not available

ND = not detect10

Decanter cake sludge: Chemical composition

Decanter cake Standard animal manufacturer feed

Substance (VCB' lab) Cow (avg.age) Pig (avg. age)

%Moisture 79.17% < 13% < 13%

Nutrient (%dry weight)

% Protein 15.27% > 14-18% > 12-18%

% Oil 2.44% > 2-4% > 2-4%

% Total P 0.29% - -

% K 1.80% - -

% Ca 1.32% - -

% Mg 0.47% - -

% Chaff N/A < 9-14% < 8-10%

Decanter Cake Nutrient analysis: compare with Malaysia data and Standard animal manufacturer feed

Source of data: Clean Technology for the Crude Palm oil Industry in Thailand, Orathai Chavalparit, 2006

Source of data: Vichitbhan’s Own Laboratory

11

Turn “Waste” into “Renewable Energy Power”

Biogas plant

Biomass power plant

Existing “Waste Utilization”

Biogas Power plant

Biogas Potential

* MW electricity calculated at 38% Efficiency biogas yield 0.45 m3/kg-CODdegradable @ 60% CH4, op. 24hr and 300 days

POME

MWThermal / yr

1,058,400 181,440,000

Source Biogas (m3) GWh Elect/a

402.2 7,200,000 m3

Amount

(Based on estimation of 12.0 million ton of FFB)

Biomass Power plant

12

VSPP Biogas plants - Power Producer from POMs

Source: VSPP_status_ March 2012, www.EPPO.go.th

Krabi, 11

Suratthani,

17

Chumporn, 6

Trang, 4

Prachup, 2

Chuonburi, 1Satun, 1

PhangNga, 1

Biogas Power Plant No.of mill in Status

(Under PPA contract) Operating On going

<1 MW 4 4

1-2 MW 12 2

2-5 MW 10 8

> 5 MW - 2

Total 26 16

13

VSPP Status Province Total No. Individual Total Capacitiy Individual PPA contract

Biomass from POMs of Plant Province Installation (MW) PPA sale (MW)

Krabi 9 20.0 14.0

Suratthani 10 17.5 15.0

Chumporn 3 10.9 9.4

Trang 4 6.7 6.0


Krabi 2 4.0 4.0

Chumporn 1 1.1 1.0

Prachuapkhirikhan 2 4.7 4.0

Chonburi 1 3.4 2.4


Chumporn 2 12.9 10.0

Satoon 1 1.0 1.0

Applied for register to PEA PhangNga 1 1.0 1.0 1.0 1.0

Total Plant 42 101.3 85.0

Signed PPA & waiting for COD 30.5 27.8


COD and in Operation 55.0 44.3

Currently VSPP_Palm Oil Biogas plant -Status

Source: VSPP_status_March2012, EPPO’s information

~ 50% of POMs in Thailand, are invested in biogas power plant

14

Biomass SPP & VSPP power plant: status by Commercial Operation Date (COD)

Fuel Type No. of plant Install

Capacity (MW)

PPA selling

capacity (MW) No. of plant

Install

Capacity (MW)

PPA selling

capacity (MW)

P a l m r e s i d u e w a s t e 4 2 4 . 0 1 9 . 7 0 - -

Bagasse 36 663.4 210.3 9 245.4 109.8

Bagasse + Rice husk 0 0.0 0.0 2 37.5 26.5

Rice husk 16 101.0 82.9 4 48.3 41.8

Rice husk+ Wood chip 0 - - 2 57.8 49

Bagass+ Wood chip+Rice husk 0 - - 2 104.9 56

Rice husk+ Corncob 0 - - 0 - -

Saw dust 1 0.6 0.6 0 - -

Coconut Bristle Fiber 1 6.0 5.0 0 - -

Corncorb 1 0.2 0.1 0 - -E F B + S h e l l + P a l m r e s i d u e 0 - - 1 9 . 9 8 . 8

Wood bark 0 - - 1 87.2 50

Scraps of wood / wood chip 7 56.5 43.7 1 23 20.2

12 38.9 37.3 22 614.0 362.1

V S P P P o w e r P l a n t : C O D a n d O p e r a t i o n S P P P o w e r P l a n t : C O D a n d O p e r a t i o n

Source of data: EPPO, SPP & VSPP status, data update until March 2012 15

“EFB Solid waste disposal site”

“From Palm Oil Mill”

Abundant of EFB solid waste

EFB ~ 2,640,000 ton/yr

Look at Biomass “palm residue Potential”

Biomass type

EFB

MWThermal / yr

5,309,333

Amount (tons)

2,640,000

GWhElect/a

1,061.9

Biomass Potential (Based on ~ 12.0 million ton of FFB per annum)

* MW electricity calculated at 20% efficiency of power plant, op. 24hr and 300 days

Shell ~ 720,000 ton/yr

Shell 2,988,000 720,000 597.6

16

Palm Oil Mill

Steam to

Palm oil mill

BOILER

Generator

Stack

Feed

Water Pump

Steam Turbine

Fiber / EFB / Shell From processes

Residue Biomass

Transformer

M

Fuel feed boiler

TURBINE

BOILER

Generator

Stack

Feed Water

Pump

CondensingTurbine

Biomass Power Plant ~ 5 MW

POME

EffElec < 24%

Existing

Eff.Elec ≤ 10%

General Existing Concept of POMs biomass PP

Biogas Plant 17

VSPP-Biomass plants from Palm Oil Residue

Source: VSPP_status_March 2012, EPPO+PEA’s information

Biomass Power Plant No.of mill in Status

(Under PPA contract) Operating On going

1-2 MW 1 1

2-5 MW 2 2

> 5 MW 2 9

Total 5 12

Krabi, 5

Suratthani, 4Chumporn, 3

Trang, 3

Prachup, 1Ratchaburi, 1

18

VSPP Status Province Total No. Individual Total Capacitiy Individual PPA contract

Biomass from POMs of Plant Province Installation (MW) PPA sale (MW)

Krabi 2 12.4 11.4


Chumporn 1 10.0 8.0

Prachuapkhirikhan 1 1.5 1.0


Krabi 2 10.0 10.0

Chumporn 2 24.6 18.0

Trang 2 19.0 15.5

Ratchaburi 1 6 4.8

Krabi 1 7.5 7.5

Trang 1 5.2 5.2

Total Plant 17 133.2 107.7


33.9 28.5

86.6 66.5

COD and in Operation

Signed PPA & waiting for COD

Currently VSPP_Palm Oil Biomass plant -Status


19

** Shell selling to be use as replace fuel of bunker oil or diesel oil in some factories in perimeter area around Bangkok and Central district **

Accruing amounts, Cost/value, and distribution

** For Empty Fruit Bunches (EFB) , average price ~ 0.12-0.15 THB/kg

Biomass cost: Shell Market Price

Shell

Mark

et

Price

(TH

B/k

g,

avg)

Month

1.50

1.60

1.70

1.80

1.90

2.00

2.10

2.20

2.30

2.40

2.50

2.60

2.70

2.80

Jan Feb March April May June July Aug Sept Oct Nov Dec

Current Price, Jan 2013

= 2.30 THB/kt

20

Prachuapkirikhan

4 Mills

Krabi -20 Mills

Surathani – 19 Mills

Chumphon

21 Mills

Satun – 5 Mills

Trang – 4 Mills

Songkha – 3 Mills

Ranong

1 Mill

NakornSrithamarah – 2 Mills

Phang-Nga

1 Mill

Biomass Distribution (cal. From FFB forecast, Sept 2012)

Chonburi

2 Mills

Total Biomass Generation in Palm oil industry

Plantation Year 2012 (B.Era 2555) Year 2011 (B.Era 2554)

Zone Shell (ton) EFB (ton) Fiber (ton) Shell (ton) EFB (ton) Fiber (ton)

Total 679,600 2,491,865 1,359,199 646,611 2,370,907 1,293,222

South 604,227 2,215,499 1,208,454 578,971 2,122,893 1,157,942

Central 68,687 251,854 137,375 63,480 232,762 126,961

NorthEast 6,052 22,189 12,103 3,860 14,152 7,719

North 634 2,323 1,267 300 1,099 600

Nongkhai– 1 Mill

Source: Forecast Agricultural Goods of year 2012/2013, Agricultural Information center, Department of Agricultural Economics, Ministry of Agriculture, Sept 2012

South: EFB 2.22 M.ton, Shell 0.60 M.ton

Central: EFB 0.25 M.ton, Shell 0.07 M.ton

Accruing amounts & Distribution

21

Estimation Biomass consumption by Existing Power Plants Operation

Krabi, 2 mill 12.4 MWe

Suratthani, 1 mill 10.0 MWe

Chumporn, 1 mill 10.0 MWe

Prachup, 1 mill 1.5 MWe

Power Plant EFB available (ton), based on FFB in Y2012

Zone Biomass avai. Existing PP requires Diff EFB

Krabi 651,512 221,179 430,333

Suratthani 651,292 179,006 472,287

Chumporn 493,599 179,006 314,593

Prachup 116,371 26,851 89,520

Total Biomass 1,912,775 606,041 1,306,733

** Currently Biomass EFB still available, enough for power plant

consumption ***

** Biomass requires calculated from MW electricity Capacity installation •at 20% efficiency of power plant, op. 24hr and 300 days

22

Future Biomass consumption by Power Plant establishing


Krabi, 5 mills 29.9 MWe

Suratthani, 4 mills 37 MWe

Chumporn, 3 mills 34.6 MWe

Trang, 3 mills

24.2 MWe

Prachup, 1 mills 1.5 MWe

Ratchaburi, 1 mill 6 MWe

Power Plant EFB available (ton), based on FFB in Y2012

Zone Biomass avai. All PP requires Diff EFB

Krabi 651,512 534,439 117,074

Suratthani 651,292 662,320 -11,028 **

Chumporn 493,599 619,359 -125,761 **

Trang 75,447 433,695 -358,248

Prachup 116,371 26,851 89,520

Ratchaburi 0 107,403 -107,403 **

Other Province 503,644 -

Total Biomass 2,491,865 2,384,067 107,798

But in future, some province area may be have limited of

EFB-biomass supply from local area

** Biomass requires calculated from MW electricity Capacity installation •at 20% efficiency of power plant, op. 24hr and 300 days 23

For more information: Contact: Tel. 02 314 - 4101- 4 Ext 612

Email: [email protected]

Conclusion and Q & A

24

Documents

Palm oil residue waste potential and waste utilization … oil residue waste potential and waste utilization in Thailand ... palm oil mill increased 36%** 4. ... Decanter cake sludge: