BIODIESEL AND RENEWABLE ENERGY FROM OIL PALM. Datuk Dr. Choo Yuen May Director-General MPOB

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1 BIODIESEL AND RENEWABLE ENERGY FROM OIL PALM Datuk Dr. Choo Yuen May Director-General MPOB POTS Korea April 2011

2 Abundance of Oil Palm Biomass Crude Palm Oil Biofuel / Biodiesel OIL PALM FRONDS FRESH FRUIT BUNCH Palm Biomass Fuel for CHP 10% oil 90% biomass OIL PALM TRUNK Palm oil mill effluent (POME) Biogas

3 Introduction on Biodiesel Driving forces for biofuels development worldwide: Environmental concerns climate change Energy security depletion of fossil fuel Support for agriculture major income to the country Fluctuation of CPO prices price stabilisation mechanism US and EU being the major countries that have aggressively produced and used biodiesel. Research on palm biodiesel in Malaysia started in 1980s. 3

4 Potential Benefit of Palm Biodiesel Support floor price of palm oil Increase in palm oil export value. Value addition from palm oil to biodiesel. Savings in foreign exchange. Multiplier effects. Reduction in pollutants (SO 2, CO, particulate matter, etc) and GHG emissions. 4

5 Malaysian Biodiesel Industry National Biofuel Policy was launched in March 2006 to provide policy framework to develop biofuels industry in Malaysia Biofuels Industry Act 2007 passed for regulation, licensing and enforcement. Ministry of Plantation Industries and Commodities responsible for issuance of biodiesel licenses and regulations. 61 licenses for biodiesel plants with total production capacity of 6.79 million tonnes per year. Current installed capacity: 2.8 million tonnes in

6 NATIONAL B5 PROGRAMME To be implemented beginning 1 June 2011 in Central Region, to be fully implemented in Central Region (Putrajaya, Kuala Lumpur, Selangor, Negeri Sembilan, Melaka) by November Building of Blending Facilities in progress RM55 million allocated for 6 petroleum terminals. Will take up 200,000 tonnes palm methyl ester. MPOB involved in planning, implementation, monitoring and providing technical support.

7 MPOB PALM BIODIESEL TECHNOLOGIES: Development Stage, Present and Future 7

8 Development of MPOB Palm Biodiesel Programme Lab scale R&D 1982 Pilot plant built and commissioned 1985 Produces palm biodiesel for engine testing and market seeding Preliminary Field Trial (July 1984 May 1985) : 8 taxis Exhaustive Field Trial (Phase I): : 31 diesel engines of different makes Exhaustive Field Trial (Phase II): : 36 buses Fully established as diesel substitute in 1995 MPOB Palm Biodiesel Pilot Plant 8

9 MPOB Palm Biodiesel Process Crude Palm Oil (CPO) Esterification Palm Biodiesel Drying Catalyst Methanol RBD Palm Oil / RBD Olein Transesterification To replace with other potential green processes Phase Separation Methanol- Recovery Ester Phase Methanol- Recovery Glycerol Phase * Water Washing Adsorbent Treatment Glycerol Treatment Crude Glycerol 9

10 Feedstock for Biodiesel Production Crude palm oil, crude palm olein and crude palm stearin Refined, bleached and deodorized (RBD) palm oil, RBD palm olein and RBD palm stearin Used frying oil Residual oil from spent bleaching earth Fatty acid distillate 10

11 Palm Biodiesel (Methyl Esters) Crude / Distilled Palm Oil Methyl Esters RBD Palm Oil Methyl Esters RBD Palm Olein Methyl Esters Winter Grade Palm Biodiesel (CFPP -21 C) 11

12 Seasonal Pour Point Requirement of Biodiesel Summer Spring Autumn Winter Season Pour Point ( C) Spring -10 Summer 0 Autumn -10 Winter -20

13 PALM BIODIESEL PLANTS (M sia) MPOB-Carotino, Pasir Gudang, Johor MPOB-Sime Darby, Carey Island, Selangor MPOB-FIMA, North Port, Selangor

14 PALM BIODIESEL PLANTS (Overseas) ENERTECH BIODIESEL PLANT, SOUTH KOREA (2006/07) NEW BIODIESEL CO. LTD., THAILAND (2008/09)

15 Opportunity in Palm Biodiesel Production: Co-Products Recovery

16 (3) Production of Value-Added Products from Palm Biodiesel For every 1 tonne of methyl esters burnt as fuel, we also burn away: 0.6 kg Carotenoids 0.8 kg Vitamin E 0.5 kg Phytosterols HO R2 R1 R3 O 0.4 kg Squalene 0.05 kg Coenzyme Q 0.06 kg Phospholipids H 3 C H 3 C O O O O H n ~US 970/tonne (RM 3,200/tonne)

17 MPOB Palm Phytonutrients Technology (partially adopted by Carotino Sdn. Bhd.) CPO NPO Esterification Transesterification Crude Methyl Esters Fractional distillation C16:0 a-sme, biodiesel C18 mixed low pour point biodiesel Vitamin E, sterols and squalene Integrated Process Distilled methyl esters High purity phytonutrients e.g. Carotenes >30% Vitamin E >70% Squalene >70% Sterols >95% Individual components e.g. b-sitosterol >95% Vitamin E isomers >95% Individual carotene >95%

18 MPOB Integrated Phytonutrients Production Pilot Plants Dry and Solvent Fractionation SC-CO 2 Chromatography Short Path Distillation Reaction SC-CO 2 Extraction

19 Products from the Integrated Process for the Production of Palm Phytonutrients Tocols (up to 95% concentration) Carotenes (up to 95% concentration) Coenzyme Q (0.3% concentration) - concentrated by 300 folds Sterols (up to 95% concentration) Squalene (up to 50% concentration) Phospholipids (0.1% concentration)

20 BIOENERGY FROM NON-OIL BIOMASS

21 Availability & Properties of Various Oil Palm Biomass Palm Shell Sample Quantity, mil. tonnes (wet basis) Moisture Content, % Calorific Value (CV), Average (MJ/kg) CV, Range (MJ/kg) Mesocarp Fibre Oil palm Biomass EFB Mesocarp fibre Shell Oil palm frond (replanting & pruning) Oil palm trunk (replanting) POME (1624 m 3 ) alm Oil Mill Effluent Other Commercial Fuels Bagasse, Cereal Straw (MJ/kg) Other Commercial Fuels (MJ/m 3 ) Natural Gas 37.9 Illinois bituminuous, Coal (Anthracite) North Dakota lignite, Coal (lignite) Reed Sedge peat LPG Empty Fruit Bunch

22 Renewable Energy (RE) Development for Oil Palm Industry Untapped Potential of Oil Palm Biomass (EFB, shell, mesocarp fibre): As fuel for combined heat and power (CHP)/power generation For conversion to transportable 1 st generation biofuels. For conversion to 2 nd generation biofuels

23 Oil Palm Biomass as Solid Fuel for Power Generation

24 Mesocarp Fibre, Palm Shell and EFB Status of Utilization as Fuel Mesocarp fibre and shell main fuels for combined heat and power (CHP) plant used in palm oil mills EFB fibre and shell being used as substitutes to fossil fuel (diesel, coal & medium fuel oil) especially in palm oil mill complex requiring extra energy for downstream activities (EFB Fibre Plant, refinery & kernel crushing plant) and other industries EFB can be upgraded into useful and uniform solid fuels (briquettes & pellet, charcoal) These biomass are main feedstocks for Small Renewable Energy Power Programme, SREP (grid connected power plant) & CDM (mitigation of Greenhouse Gases, GHG) projects

25 Technology for Palm Biomass Solid Fuels EFB Pretreatment Plant for EFB Fibre (Fuel Preparation) EFB requires physical pretreatment to reduce size and moisture content to enable EFB be more efficient to be used as fuel EFB in fibrous form can be potential a feedstock for various technology of solid fuels or for 2 nd Generation Biofuel Briquetting & Pelletizing process of compressing/ compacting the loose biomass into higher density fuels in shape of briquette and pellet via mechanical treatment for easy handling, transportation and storage of material. Typical diameter sizes : briquettes Ø < 9cm, pellet Ø <1cm Can be further treated into charcoal or torrefied pelelt / briquette Torrefaction & Carbonization process of heating of biomass in the absence of O 2 to a temperature of º C within certain retention time. The process will reduce the weight of the biomass and increase the CV. The loose torrefied and carbonized biomass could be pelletized into uniform fuel

26 EFB Pre-Treatment Technology for Fuel Preparation EFB Screw press cum shredder Hammer mill Dry and short EFB Fibre as feedstock for the production of briquettes and pellets fuel EFB Juice for Oil Recovery EFB fibre as fuel Post Treatment Drying Biomass boiler / power generation

27 Uniform-Solid Fuels from Oil Palm Biomass (EFB Fibre, Briquettes & Pellets) Palm biomass briquettes piston press technology Biomass Pellet Charcoal briquettes Characteristics: Calorific Value kj/kg Moisture content < 6.0% Ash content < 6.0% Specific Density kg/m 3 Palm Biomass Briquettes Screw Extrusion Technology Fibrous EFB & Bale Torrefied Pellet

28 Second Generation Biofuels Palm Lignocellulosic Biomass

29 Biomass to Liquid (BTL) Bio-oils Synthetic diesel Bioethanol/Biobuthanol Hydrocarbon fuel Transport Fuel **Pre-Treatment Carbonisation Slow & Fast Pyrolysis Rapid Thermal Processing (RTP) BTG Thermal/Catalytic depolymerisation Fermentation/Catalysis Thermomechanical/Thermochemical, acid or enzymatic hydrolyses, mechanoenzyme Hydrotreating Catalytic cracking Hydrocracking Gasification-Pyrolysis-Fischer-Tropsch Tedious and energy intensive due to difficulty in breaking the complicated cell wall of palm biomass.

30 Commercialization of 2nd Generation Biofuel Under NKEA palm oil sector: one initiative is to set up commercial bio-oil plant using EFB as feedstock. Plant will generate electricity for grid connection.

31 Pyrolysis of Palm Biomass Products: - Bio-oil, biochar and gas Properties of bio-oil Calorific Value (MJ/kg) Temperature ( C) Total Ash, % ph Moisture (%) Density (g/cm 3 ) MPOB Pyrolysis Experimental Rig Type of Oil Palm Biomass Bio-oil (%) Char (%) Gas (%) EFB Trunk Frond Shell Biochar Bio-oil

32 Catalytic Depolymerisation (CDP) of Palm Biomass Product: - Synthetic Diesel Cracked The catalyst cracks the long molecular chains of the hydrocarbons and shortens them in a specific way The CH2-Molecule structure remains and the molecule length is only reduced (optimally on C15) Wood / EFB Malaysian municipal solid waste Organic Waste With Used Oil

33 Fermentation of Palm Biomass Product: lignin, fermentable sugars, bioethanol Stage 1: Pre-treatment Fractionation of lignocellulosic component of EFB by using thermo-mechanical/chemical digestion process Sustainable conversion of palm biomass to bioethanol through biotechnological advances Stage 2: Sugars hydrolysis & extraction Production of fermentable sugars from palm biomass (EFB) as bioethanol feedstock Stage 3: Fermentation Fermentation of sugars from EFB to bioethanol Special microorganism is required to break open the cell wall to convert cellulose to glucose/xylose.

34 Bioethanol Production from Empty Fruit Bunches (EFB) Inoculated with microbe Treated Palm Biomass (Hydrolysate) Incubation Mixture of fermentation product (bioethanol) Distillation at 75ºC Fermentation broth Analysis

35 Bioethanol Production from Oil Palm Trunk Oil palm trunk Removal of bark Sample analysis (moisture content, sugar content and fermentation) Mechanical extraction (pressing )

36 Potential Hydrocarbon Fuel from Palm Biomass Thermal cracking Catalytic cracking Hydrocraking Potential cracked products: saturated & unsaturated hydrocarbons C5 C17 Potential use as gasoline substitute (Aviation Fuel)

37 Biomass to Gas (BTG) Producer gas/ Syngas Biogas (POME) Biomethane Biohydrogen Combustion Gasification BTG Anaerobic Digestion Fermentation Fuel cell (Catalytic process)

38 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: Empty fruit bunches, palm shell and fiber Process optimization in progress to achieve: H 2 (40%); CO (30%); CH 4 (10%)

39 Biogas from Palm Oil Mill Effluent (POME) About m 3 of POME is generated for every 1 tonne of FFB processed 56 million tonnes of POME generated in 2009 Biogas is produced during the decomposition of organic matters in anaerobic pond It contains about % Methane (CH 4 ), % Carbon Dioxide (CO 2 ) and trace amount of Hydrogen Sulphide, (H 2 S) Methane - the global warming potential 21 times higher than CO 2 Potential yield: 1 m 3 of completely digested POME produces m 3 biogas 1624 million m 3 of biogas generated in 2009 GHG emission reduction: million tonnes CO2 eq. CH 4 CH 4 CO 2 CO 2 CH 4

40 Trapping of Biogas at Palm Oil Mills Under NKEA palm oil sector: all palm oil mills to have methane trapping facilities by million tonnes of carbon dioxide equivalent per year mitigated

41 Biogas Plant at Palm Oil Mills Two technologies: digester and covered lagoon Biogas application: - Electricity generation - on & off grid - CHP - steam and heat - Co-firing in biomass boiler and diesel genset to reduce the utilization of the palm shell and diesel Power potential: 1-2 MW from 60 t/hr POM Ponding system of POME treatment

42 POTENTIAL BIOGAS UTILIZATIONS IN PALM OIL MILLS OPTIONS OF UTILIZATION Diesel Engine (cofiring) Electricity Gas Engine Electricity Co-firing in biomass boiler Gas engine for electricity Micro Turbine Electricity POME Cleaning Biogas / Methane Package Boiler / Biomass boiler (cofiring) Flare Electricity Steam Cooling Mixing Anaerobic Aerobic Land application Composting Water course Biogas capturing technology cover lagoon and digester tank Composting / biofertilizer

43 Avoidance of Methane Methane avoidance: 1. Co-Composting: EFB co-compost with POME/decanter cake and boiler ash 2. Utilisation of Non-oil Component: - Sampling of non-oil phase after the screw pressing - The low oil fraction showed that it can be used as a food source

44 Issues & Challenges

45 Issues on Renewable Energy from Oil Palm Biomass / Biogas as Fuel Competitiveness uses of biomass for non-energy products Interconnection issue / cabling cost / load demand and safety location of the power plants (for grid connected power plant) Uncertainties of long terms biomass supply & pricing mechanism, logistic and transportation cost Unnecessary bureaucratic requirements the need for one-stop centre, competent local personnel Need for more financial support / incentives / simplified REPPA Inconsistency of biomass fuel quality EFB pre- treatment plant Inefficient / low efficiency of CHP used in palm oil mills increment of efficiencies may generate excess energy and revenue (save palm biomass)

46 Way Forward

47 Towards Zero Wastes /Reduced Emissions METHANE TRAPPING POME Biogas Sedimentation pond Biogas System Direct Application Solid Sludge Composting Electricity Steam Sedimentation pond Aerobic Digestion EFB Biofertilizer Decanter Cake Gas engine boiler Towards innovating less energy intensive pretreatment technology Discharge of effluent, Land Application Nanofiltration Drinking Water

48 Conclusion The palm oil industry, though producing mainly palm oil for food applications also uses palm oil for biodiesel production. The industry also produces huge amounts of non-oil biomass residues which can be used for renewable energy. A zero waste approach is pursued for sustainability.

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