Renewable Energy from Oil Palm. Academician Tan Sri Datuk Dr. Augustine S.H. Ong 27 November 2006

Transcription

1 Renewable Energy from Oil Palm Academician Tan Sri Datuk Dr. Augustine S.H. Ong 27 November 2006

2 Oil Palm Plantation

3 Plantation Palm Tree Fresh Fruit Bunch

4 National Energy Demand Year National Energy Demand (MW) Electricity Generated by Palm Oil Mills (kwh) Electricity Generated by Palm Oil Mills (MW) , million 301 Source: Ir. Ravi Menon (2006)

5 Energy from Palm Biomass Palm biomass comprises Empty Fruit Bunches (EFB), Fibre, Shell, Trunk and Frond. Fibre, shell and EFB (to a limited extent) are used as boiler fuel in all palm oil mills to generate steam and electricity for own consumption only. Though in existence for more than 40 years, it is not commercially recognized as it was never connected to grid for sale.

6 Biomass from Palm Oil Mills in 2005 Biomass Quantity ( ) Empty fruit bunches (EFB) Palm Fibre Palm Shell Palm Oil Mill Effluent (POME) 19.5 tonnes 11.9 tonnes 5.9 tonnes 51.6 m 3

7 Empty Fruit Bunches 19.5 million tonnes in 2005

8 Palm Fibre 11.9 million tonnes in 2005

9 Palm Shell 5.9 million tonnes in 2005

10 Palm Shell and Fibre as Boiler Fuel

11 Energy Database for Palm Biomass Sample Calorific Value (kj/kg) Ash (%) Volatile Matter (%) Moisture (%) Hexane Extractable (%) EFB 18, Fibre 19, Shell 20, POME 16, Source: Chow et al. (2003)

12 Conventional Methods of Preparation of Methyl Esters Fat Splitting of Glycerides into Fatty Acids followed by Esterification. Base-Catalysed Transesterification of Glycerides

13 MPOB / PETRONAS Patented Palm Biodiesel (Methyl Esters) Process 1. Esterification of free fatty acids present in crude palm oil, crude palm stearin and crude palm kernel oil into methyl esters with solid catalyst. RCOOH + MeOH RCOOMe + H 2 O 2. Transesterification of neutral glycerides into methyl esters in the presence of base catalyst. CH 2 OCOR 1 R 1 COOMe CH 2 OH CHOCOR 2 + MeOH R 2 COOMe + CHOH CH 2 OCOR 3 R 3 COOMe CH 2 OH

14 3000 tpy Palm Biodiesel Pilot Plant at MPOB

15 Palm Biodiesel Pilot Plant Official Launching of Pilot Plant by Y.A.B. Honorable Prime Minister of Malaysia : Oct 1985 To Supply Palm Biodiesel for Field Trial Capacity : 3,000 tpy of Palm Biodiesel Continuous Plant - able to process palm oil with high free fatty acids content.

16 Palm Biodiesel Pilot Plant

17

18 RBD Palm Oil Methyl Esters RBD Palm Olein Methyl Esters

19 Key Fuel Properties of Palm Biodiesel Property Palm Biodiesel Malaysian Petroleum Diesel Density at 15 C (kg/l) ASTM D Sulfur Content (% wt) IP C (cst) ASTM D445 Pour Point ( C) ASTM D97 Flash Point ( C) ASTM D93 < Cetane Number ASTM D Gross Heat of Combustion (kj/kg) ASTM D2332 Conradson Carbon Residue (% wt) ASTM D198 40, ,

20 Exhaustive Field Trials using Palm Biodiesel Successfully conducted between on diesel engines of different makes and models. Trials involved 30 buses mounted with Mercedes Benz OM352 Engine: 100% palm diesel (10 buses) 50% : 50% blend (10 buses) 100% Petroleum Diesel as control (10 buses) Results in terms of engine performance, fuel consumption, exhaust emission, repair and maintenance were promising.

21 Field Trials using Various Diesel Engines

22 Field Trials using Mercedes Benz (OM352) Diesel Engines Mounted on Passenger Buses (each bus covered 300,000 km)

23 On The Road with Palm Biodiesel TANJONG MALIM ULU PAKA K.SELANGOR K.LUMPUR CHERAS KUALA LUMPUR PAJERO LEN OMNIBUS SELANGOR OMNIBUS TOONG FOONG OMNIBUS KLUANG

24 Smoke Emission from Passenger Bus using Petroleum Diesel

25 Clean Smoke Emission from Passenger Bus using Palm Biodiesel

26 Emission Test of Palm Diesel and Blends of Palm Biodiesel / Petroleum Diesel Blend of 50% petroleum diesel/50% Palm Biodiesel) 100% Palm Biodiesel HC SMOKE

27 Summary Of Field Trial No modification of conventional diesel engine required. Performance of engine : good. Easy starting, no knocking, smooth running. Exhaust gas emission : much cleaner (reduction of hydrocarbon, CO, CO 2, SO 2 content.) More environmentally friendly. Engine oil: still usable after recommended mileage. Cetane number / Diesel Improver ( 62.4 c.f 37.7 for petroleum diesel from Europe)

28 (cont ) Summary of Field Trial Palm diesel : higher flash point (174 o C c.f. 98 o C for petroleum diesel) offers enhanced safety in terms of storage and transportation. Carbon build up in engine fuel nozzle : normal except nature of carbon different. Fuel consumption of palm diesel : comparable with petroleum diesel (e.g. 3 4 km per liter for bus tested).

29 Recent Trials using Palm Diesel on Commercial Trains Trials conducted by Prignitzer Eisenbahn (PE) Arriva in Germany, since September 2004.

30 Summary of Field Trials (Commercial Trains) No problem concerning carbon No deposit in combustion chamber No changes in motor oil No problem with materials in fuel system

31 Phytonutrients: Opportunities

32 Value-Added Products 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 0.4 kg Squalene 0.05 kg Coenzyme Q 0.06 kg Phospholipids

33 Value-Added Products The values of the phytonutrients are: Carotenoids (30%) US300/kg Vitamin E (50%) US500/kg Phytosterols (Industrial Grade) (as β sitosterol) Squalene (Nutraceutical Grade) Coenzyme Q (Pharmaceutical Grade) Phospholipids (Nutraceutical Grade) US25/kg US33/kg US2,800/kg US25/kg

34 Value-Added Products For every 1 tonne of methyl esters burnt as fuel, the value of phytonutrients burnt away is: ~US 970/tonne (RM 3,686/tonne)

35 Production of Phytonutrients from Palm Diesel using MPOB Technologies

36 Crude Palm Oil ( CPO ) CPO Methyl Esters (Palm Diesel) Distillation Distilled Methyl Esters (Palm Diesel) Phytonutrients Concentrate Containing Carotenes, Tocols, Phospholipids (Lecithin), Sterols, Coenzyme Q and Squalene Feedstock for value-added oleochemical products Carotenes Tocols Sterols Squalene Coenzyme Q Phospholipids (Lecithin)

37 Production of Individual Carotene, Tocols & Cholesterol-free Sterol High purity (>95%) of the following produced: individual carotene, e.g. α- and β- carotenes, lycopene and phytoene individual tocols isomers, e.g. α- and γ-tocopherols, α-, γ- and δ- tocotrienols β-sitosterol + +

38 Development of Low Pour Point Palm Biodiesel Palm Biodiesel (Crude / Distilled Palm Oil Methyl Esters) Low Pour Point Palm Biodiesel

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

40 Key Fuel Characteristics of Normal Palm Biodiesel and Low Pour Point Palm Biodiesel Property Normal Palm Biodiesel Low Pour Point Palm Biodiesel Petroleum Diesel Density at 15 C (kg/l) ASTM D Sulfur Content (% wt) IP C (cst) ASTM D445 Pour Point ( C) ASTM D97 Flash Point ( C) ASTM D93 < 0.04 < Cetane Number ASTM D Gross Heat of Combustion (kj/kg) ASTM D2332 Conradson Carbon Residue (% wt) ASTM D198 40,335 39, ,

41 Fuel Properties of Palm Biodiesel vis-à-vis EN14214 & ASTM D6751 Properties Unit EN ASTM D6751 Palm Biodiesel Min Max Min Max Ester Content % mass Density at 15 C g/cm Viscosity at 40 C cst Flash Point C Sulphur Content % mass <0.001 Carbon Residue (on 10% distillation residue) % mass Cetane Number Oxidative Stability, 110 C Copper Strip Corrosion (3h at 50 C) hours >6 rating a EN14214: European Standard for Biodiesel ASTMD6751: Standard Specification for Biodiesel Fuel (B100) Blend Stock for Distillate Fuels

42 Fuel Properties of Palm Biodiesel vis-à-vis EN14214 & ASTM D6751 Properties EN ASTM D6751 Unit Min Max Min Max Palm Biodiesel Sulphated Ash Content Basic Sediment and Water % mass <0.01 % mass <0.05 Acid Value mg KOH/g Pour Point C Report Report 15 Iodine Value Content of Linolenic Acid Methyl Esters Content of Polyunsaturated Methyl Esters (more than 3 double bonds) % (m/m) <0.5 % (m/m) <0.1 EN14214: European Standard for Biodiesel ASTMD6751: Standard Specification for Biodiesel Fuel (B100) Blend Stock for Distillate Fuels

43 Fuel Properties of Palm Biodiesel vis-à-vis EN14214 & ASTM D6751 Properties Unit EN ASTM D6751 Palm Biodiesel Min Max Min Max Methanol Content % (m/m) <0.2 Monoglycerides % (m/m) <0.4 Diglycerides % (m/m) <0.2 Triglycerides % (m/m) <0.1 Free Glycerol % (m/m) <0.01 Total Glycerol % (m/m) <0.01 EN14214: European Standard for Biodiesel ASTMD6751: Standard Specification for Biodiesel Fuel (B100) Blend Stock for Distillate Fuels

44 Environmental Impact of Palm Biodiesel Environment-friendly great reduction in CO 2, CO, total unburnt hydrocarbon, SO 2, particulates and air toxics Biodegradable Renewable Improved air quality and greenhouse gas mitigation reduction in health care costs In-line with Clean Development Mechanism (CDM) of 1997 Kyoto Protocol.

45 Production and Consumption of Palm Biodiesel: A Closed Carbon Cycle Carbon Dioxide Emission Palm Biodiesel Vehicles Consumption

46 Production of Palm Biodiesel (from Pilot Plant to Commercial Plant)

47 3D Plant Layout for Palm Biodiesel Plant (60,000 tpy)

48 MPOB-LIPOCHEM Biodiesel Plant Feedstock Specification Specification RBD Palm Oil RBD Palm Olein FFA (as palmitic) (%) 0.1 max. 0.1 max. Moisture & Impurities (%) 0.1 max. 0.1 max. Iodine Value 50 to min. Melting Point (AOCS Cc-25) ( C) Colour (5 ¼ Lovibond Cell) 33 to Red max. 3 Red max. Note: RBD refined, bleached and deodorized

49 3D Plant Layout for Low Pour Point Palm Biodiesel Plant (based on 30,000 tpy feedstock)

50 Indicative Costs for the Production of Normal Palm Biodiesel in Malaysia Capital Cost: 10,000 tonnes per year USD 4 million 60,000 tonnes per year USD 12 million Cost (USD) per tonne Biodiesel Ex-Factory Medium Sized Plant USD Refined Feedstock Costs 400 Processing Costs 70 Depreciation 40 By-Product Credit 20 Cost USD/tonne Ex-Factory 490 Cost to Importing Country Add: FOB Charges Shipping Freight & Costs Import Country Duty Discharge Port and Storage Distribution Cost & Margin Retail Cost & Margin = Pump Price Cost EUR/litre Ex-Factory 0.36

51 Biodiesel Profitability Sensitivity Product Price High Feedstock Price High Glycerol Price Moderate Methanol Price Moderate Processing Cost Low Capital Cost Low Indicative Profitability IRR 30 45% Payback 1.5 to 2.5 years from production start Selling Price Biodiesel sold to Europe at EUR0.50/litre

52 Indicative Costs for the Production of Low Pour Point Palm Biodiesel in Malaysia Capital Cost: 30,000 tonnes per year USD 3.5 million USD Feedstock Costs 490 Processing Costs 40 Depreciation 10 Cost USD/tonne Ex-Factory 540 to Importing Country Cost EUR/litre Ex-Factory 0.40 Selling Price Low Pour Point Palm Biodiesel Sold to Europe at EUR0.50/litre Cost to Importing Country Add: FOB Charges Shipping Freight & Costs Import Country Duty Discharge Port and Storage Distribution Cost & Margin Retail Cost & Margin = Pump Price Indicative Profitability IRR 25 30% Payback 2 to 3 years from production start

53 Potential Renewable Energy being Developed

54 Biogas from Palm Oil Mill Effluent (POME) Biogas (65% CH 4, 35% CO 2 ) gaseous product from anaerobic digestion of POME About 28 m 3 per tonne of POME treated Calorific value 4740 kcal/m 3 Ready gaseous fuel for gas engine, boiler and burner A potential 5 th fuel source in SREP

55 Biogas Product from Anaerobic Digestion of POME Good Energy Resource but Untapped

56 Some Properties of Gaseous Fuels Properties Gross calorific value (kj/nm 3 ) Biogas Natural gas Liquefied Petroleum Gas 19,908 25,830 3, ,500 Specific gravity Ignition temperature ( C) Inflammable limits (%) Combustion air required (m 3 /m 3 ) Source: Quah and Gillies (1981)

57 Fischer-Tropsch Process The original chemical equation: (2n + 1) H 2 + nco C n H 2n+n + nh 2 O The initial products (i.e. CO and H 2 ) can be produced by: (1) Combustion of methane: CH 4 + ½ CO 2 2H 2 + CO (2) Gasification of coal or biomass CH + ½ O 2 ½H 2 + CO

58 Pilot Plant Unit for the Production of Bioethanol from Cellulosic Biomass Source National Renewable Energy Laboratory (NREL) in Golden, Colorado

59 Palm Briquettes A clean, uniform and quality fuel Improves handling, physical, chemical and combustion characteristics Save cost in biomass disposal and storage, turn waste into wealth

60 Acknowledgement I would like to express my deepest appreciation to Dr. Choo Yuen May and Ms. Puah Chiew Wei of the Malaysian Palm Oil Board for their expert assistance in the preparation of this lecture.

61 THANK YOU