Megasonics (High Frequency Ultrasound) in the Palm Oil Industry - The Power of Partnerships
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1 Megasonics (High Frequency Ultrasound) in the Palm Oil Industry - The Power of Partnerships CSIRO: MA Augustin, P Juliano, P Clarke, P Swiergon, R Mawson, K Knoerzer IHMS: KH Lee and Team Ladang Tai Tak: Calvin Ho, CW Ho and Team BioBorneo 2013, Kota Kinabalu, Malaysia, th February 2013
2 Outline The Opportunity Building the concept through partnerships The Science and Technology Does it work? - Trials at CSIRO (Australia) - Trials in Palm Oil Mill (Ladang Tai Tak, Malaysia) The Way Forward 2 BioBorneo 2013
3 CSIRO - Who we are Darwin People 6500 Cairns Atherton Townsville 2 sites Divisions 12 Alice Springs Rockhampton Locations Flagships Budget $1B+ Perth 3 sites Murchison Geraldton 2 sites Adelaide Toowoomba Gatton Myall Vale Narrabri Parkes Mopra Irymple Griffith 2 sites Sydney 5 sites Wodonga Werribee 2 sites Belmont Geelong Newcastle Bribie Island Armidale 2 sites Canberra 7 sites Melbourne 5 sites Brisbane 6 sites Top 1% of global research institutions in 14 of 22 research fields Top 0.1% in 4 research fields 3 BioBorneo % of our people hold university degrees 2000 doctorates 500 masters Hobart Sandy Bay With our university partners, we develop 650 postgraduate research students
4 Our Business Units FOOD, HEALTH & LIFE SCIENCE INDUSTRIES ENERGY ENVIRONMENT INFORMATION & COMMUNICATIONS MANUFACTURING, MATERIALS & MINERALS 11 National Research Flagships + National Research Facilities and Collections 12 Research Divisions + Transformational Capability Platforms 4 BioBorneo 2013
5 Global Connections: impact partnerships 80 + countries China Australia Alliance for New Energy Vehicle Innovation 5 BioBorneo 2013
6 Our Track Record: top inventions 2. POLYMER BANKNOTES 3. RELENZA FLU TREATMENT 4. EXTENDED WEAR CONTACTS 1. FAST WLAN Wireless Local Area Network 5. AEROGARD 6. TOTAL WELLBEING DIET 7. RAFT POLYMERISATION 8. BARLEYMAX 9. SELF TWISTING YARN 10. SOFTLY WASHING LIQUID 6 BioBorneo 2013
7 The Opportunity Science meets business The Industry Issue Inherent loss of oil in palm milling and oil in mill effluent stream Decrease oil loss = Increase in profitability and positive environment impact Why Megasonics? Enhanced extraction of oil from vegetal material Facilitation of oil separation from mixtures (De-emulsification of oil) Opportunities for Interventions Literature reports indicate potential for food processing (Mason et al., 1996, Ultrasonics Sonochemistry 3, S253) Patents (Adnan et al., WO2010/ A1, Applicant Cargill; Augustin et al., TW8611/PCT. Applicant CSIRO) 7 BioBorneo 2013
8 Building the Partnership 8 BioBorneo 2013
9 Building the Partnership Identifying the Players CSIRO - US applications in food processing Science Expertise Ladang Tai Tak - Palm oil milling operations Best Practice IHMS Many years of experience in the palm oil industry Trusted Advisor Sonosys Technology supplier Application specifics Developing a shared Vision Improving palm oil milling operations by application of sound science Protection of Intellectual Property (IP) Agreed path for mutual benefit - for science and translation to industry Smart partnerships need to built on trust and open communication amongst partners whilst focusing on practical commercial outcomes 9 BioBorneo 2013
10 Building the Partnership How we went about it? Face-to-face meetings Defined the issue for the palm oil milling industry & significance of improving oil recovery Educating each partner IHMS/Tai Tak provided information and shared experiences in palm oil milling CSIRO provided information and shared experience in ultrasound processing Sonosys responded to application specific requirements Always open communication at each stage of development Test concept on small scale (CSIRO, Australia) and on larger scale at Tai Tak Mill (Malaysia) 10 BioBorneo 2013
11 The Science and Technology Does it work? - Trials at CSIRO (Australia) 11 BioBorneo 2013
12 The Science and Technology Does it work? The Underpinning Science De-emulsification of model milk emulsions (Juliano et al (2011), Ultrasonics Sonochemistry, 18, 963) Trials at CSIRO Feeds Ex-screw press feed, Underflow sludge, Palm oil mill effluent Ultrasound treatment Low (20 khz) and High frequency (up to 2 MHz) Trials at Tai Tak Larger scale Pilot scale Batch process Small scale Commercial Continuous process 12 BioBorneo 2013
13 Early Work: Technology development in model milk system Megasonics causes agglomeration and creaming of fat globules in an emulsion Juliano et al (2011) Ultrasonics Sonochemistry, 18, BioBorneo 2013
14 Preliminary Trials - Testing the concept at CSIRO Palm Oil Mill Samples (Air-freighted from Ladang Tai Tak) 1. Ex-screw press feed 2. Underflow sludge (ex-clarifier tank) 3. Palm oil mill effluent Ultrasound (US) Experiments (Laboratory / Pilot-plant scale at CSIRO) 1. Low frequency US 2. High frequency US (Megasonics) 3. Combination of (Low + High Frequency) US 14 BioBorneo 2013
15 Design of Ultrasound Trials Small scale T = 70ºC Remove top oil layer Heat sample 85ºC Low Frequency US High Frequency US (Megasonics) Gravity Settling in tubes 1 h at 85ºC Measure Top oil layer Centrifugation At 1000g Measure Oil in Top Layer Oil Combined Low & High Frequency US Control No US Assessment of US efficiency: Oil recoverable (After gravity settling + After centrifugation) 15 BioBorneo 2013
16 Ex-Screw Press Feed: Effect of Megasonics Control Megasonic treated High frequency - Megasonic treatment: Increases amount of oil after gravity settling Clarification occurs more efficiently 16 BioBorneo 2013
17 Underflow Sludge: Effect of Megasonics Control Megasonic treated High frequency Megasonic treatment: Increases amount of oil after gravity settling Clarification occurs more efficiently 17 BioBorneo 2013
18 Palm Oil Mill Effluent: Effect of Megasonics After 1 hr megasonic processing POME Oil Separation in De - oiling Tank ( > 1 month) - No Ultrasound Megasonic treatment: Pools of oil floating on top of POME after megasonic treatment Small amount of oil in POME - Requires testing on larger scale 18 BioBorneo 2013
19 Preliminary Trials at CSIRO Concept tested Potential of High Frequency Ultrasound (Megasonics) Intervention Established Ex-screw press Increased oil yield Increase obtained dependent on inherent feed characteristics Underflow sludge Increased yield Higher risk of re-emulsification (compared to ex-screw press feed) Palm oil mill effluent Difficult to quantify oil released Pools of oil floating on top of sample after ultrasound 19 BioBorneo 2013
20 The Science and Technology Does it work? - Trials in Palm Oil Mill (Ladang Tai Tak, Malaysia) 20 BioBorneo 2013
21 Trials in Palm Oil Mill (Ladang Tai Tak) Pilot scale Ex-screw press feed Oil Layer Oil Layer Decantable Oil Control Decantable Oil After Megasonics Tank for Treatment Estimation of oil release - Centrifugation 21 BioBorneo 2013
22 Megasonic Effects on Ex-screw Press Feed (Pilot scale trials in palm oil mill 100L) Oil separated (kg) Control Day 2 US Day 2 Megasonics: Rapid oiling-off Oil separated (kg) Control Day 3 US Day 3 Megasonics: Rapid oiling-off Settling time (min) Control: No oiling-off Settling time (min) Control: Slow oiling-off Megasonic treatment enhanced rate of oiling-off from ex-screw press feed 22 BioBorneo 2013
23 Megasonic Effects on Ex-screw Press Feed (Pilot scale trials in palm oil mill 100L) Sample Control Megasonic Application Feed oil content 35.4% a 33.1% a Oil in sludge (bottom) 29.1% a 10.0% b Ex-centrifuge sludge oil 4.6% a 2.6% b Average of 6-8 runs; Numbers within rows followed by different alphabets are sigfnicantly different (p<0.05) Feed in the control test tank and the ultrasound test tank had the same oil content Bottom sludge from the megasonic tank had lower oil content Oil content in the centrifuged sludge for the megasonic tank was significantly lower than that of the centrifuged sludge for the control tank Megasonic treatment enhanced oil recovered from ex-screw press feed 23 BioBorneo 2013
24 Megasonic Effects on Sludge Ex-VCT (Limited Pilot scale trials in palm oil mill 100L ) Sample Control Megasonic Application Feed oil content 9.33 % a % a Oil in sludge (bottom) 9.24 % a 9.56 % a Numbers within rows followed by the same alphabet are NOT significantly different (p>0.05); ie Means are the same Difference between feed oil content and oil content in bottom sludge Control 0.09% Megasonic 0.44% Some evidence of enhanced separation with megasonic treatment BUT differences are NOT significant More work required to determine value of megasonic treatment of sludge Ex-VCT 24 BioBorneo 2013
25 Megasonic Treatment : Oil quality maintained (Pilot 100L runs Aug 2011) Averages Megasonics* Commercial Crude Oil FFA (%) 4.33 ± DOBI value 2.53 ± α-t (mg/kg oil) 177± Σ T3 (mg/kg oil) 773± Σ Vit. E (mg/kg oil) 950± α-t: T ± * Values are the average of 5-6 independent runs 25 BioBorneo 2013
26 Semi Commercial Scale 5 ton/hr Megasonic Reaction Chamber Generators Partnership Plant 26 BioBorneo 2013
27 Megasonic Assisted Oil Recovery Summary (5 t / hr Semi commercial scale) Method of analysis SSD difference in oil loss (kg oil/ton FFB) % Oil recovery efficiency difference on SSD NIR % Spin test % Average % Megasonic application increases oil recovery Commercialisation of technology 27 BioBorneo 2013
28 Megasonic Treatment : Oil quality maintained (5 ton/hr versus commercial Aug Sept 2012) Component 1 Commercial 5 ton / hr plants VCT Control Megasonics α-t ± ± ± 15.1 α-t ± ± ± 19.8 β-t ± ± ± 4.9 γ-t ± ± ± 42.8 δ-t ± ± ± 16.4 Total T ± ± ± 82.0 α-t : T3 0.2 ± ± ± 0.01 Total Vit. E ± ± ± Values are the average of 8 independent day runs 28 BioBorneo 2013
29 Megasonics Treatment: Other benefits Not Quantified as Yet Increased speed of oil recovery faster throughput $ value Lower load on centrifuge Low maintenance on centrifuges = Longer life $ value Lower load and BOD in POME Less impact on environment $ value 29 BioBorneo 2013
30 The Way Forward 30 BioBorneo 2013
31 Industry Open Day Sept ton/hr plant 31 BioBorneo 2013
32 Estimates of $ Benefits in Palm Oil Milling World production 50 to 60 million T Assumptions: - Palm oil selling price of US$750 per T - Yield increase of oil between 0.5 and 1.0% (could be higher in some plants) Malaysian production is some 16 million T Between 400 and 500 mills in Malaysia In Malaysia 40,000 T per average plant = US$30 million value % increase = T = US$ ,000 / yr / plant 32 BioBorneo 2013
33 Commercialisation Business model for megasonic technologies spin off Other (e.g. Marketing, PR) Sonosys (technology) IHMS (consultancy) R&D - Project 1 (MS) - Project Project X (etc) Spin off technologies Commercialisation company - multiple arrangements - company specific Palm oil mills CSIRO (consultancy) Tai Tak (infrastructure) 33 BioBorneo 2013
34 Summary Megasonics has benefits to offer the palm oil industry Better efficiency Positive environmental impact Partnerships are great vehicles to grasp ideas to develop applications to prove concepts to check commercial reality There is more to be done There is more to be learnt There is more to be gained But now is the time to act! 34 BioBorneo 2013
35 Additional Acknowledgements The team would like to acknowledge the contributions from the following: CSIRO Chris Downs (Business) IHMS Teoh Guan Eng (Training & Technology) Maria Othman (Admin & Finance) Tai Tak Clinton Ho (Administration) Narendaran ( Mill Assistant Engineer) Palm Neutraceuticals - Gee Ping Tou Matrix Analytical technologies - Thong Meng Chil 35 BioBorneo 2013
36 Thank you CSIRO Animal, Food and Health Sciences Phil Clarke Deputy Chief, Operations t e phil.clarke@csiro.au
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