cocoethanol progress report (january-june 10, 2011
TRANSCRIPT
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COCO-ETHANOL PROJECT PROGRESS REPORT
(A SUB-PROJECT UNDER COCONUT BIOMASS PROJECT)
Melencion1, N.J. and L.J Penamora
2
Timber Utilization DivisionPCA-Zamboanga Research Center
San Ramon, Zamboanga City
Period Covered: January 1, 2011 to June 9, 2011
ExecutiveSummaryThe Coconut-Based Ethanol Project (CocoEthanol) was conceptualized to adapt and
fine tune existing ethanol production technologies. In the process, it is envisioned that newer
technologies suited to Philippine conditions will be generated to help utilize every available
coconut-based feedstocks for bioethanol production. It was first proposed in 2009 but was
funded only in the late December of last year. It was tucked as a sub-project under the
Coconut-based Biomass Utilization Project.
Coco-ethanol project is designed to be implemented in two stages due to the huge
project cost (P10-20M) required in establishing a laboratory capable of doing researches on
lignocellulosic ethanol. The first stage of the project involves the use of simple equipmentand easy fermentable feedstock sugars from inflorescences of coconut, sugar palm
(Arenga pinnata/cabo negro/kaong/kalong-kaleng), and pugahan (Karyota urens). A
proposal along this line entitled Enzymatic bioethanol production from toddies of different
coconut cultivars was reviewed and approved by the Project Review Committee and
subsequently endorsed by the then PCA Administrator Oscar Garin to the DA-Biotechnology
Unit for possible funding last July 15, 2010. The proposal, however, did not get the funding it
sought. Likewise, fermentable sugars from tubers that can be grown as coconut intercrops
will also be evaluated in the first phase of the project. These tubers include ube (Dioscorea
alata), camote (Impomoea batatas), cassava (Manihot eculenta), and yakon (Smallanthus
sonchitolius). Second stage calls for specialized (and costlier) equipment and chemicals for
the biological handling/treatments required to reduce cellulose and hemicelluloses in
coconut biomass (leaves, stem, husks, and other plant materials generated in coconut
cultivation) into simple sugars for subsequent fermentation and distillation.
_______1Science Research Specialist II;
2Division Chief III
Republic of the PhilippinesPhilippine Coconut AuthorityZamboanga Research CenterSan Ramon, Zamboanga City 7000P.O. Box 356 Tel/Fax No. 062 982
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To date, the preparation and furnishing of a basic laboratory is almost complete. A
simple pot still/reflux distiller was also fabricated locally as no equipment outlay was
released for the said project. The successful fabrication and testing of the PCA-ZRC distiller
enables the project to conduct fermentation trials as we can now separate ethanol from the
fermented brew. Estimated manufacturing cost of the said distiller is about P10,000 to
P15,000.
The PCA-ZRC Distiller was first tested last April 28, 2011 using tuba from coconut.
The distillation rate is about 20.58mL of ethanol per minute or roughly 1.2L per hour.
Distillate purity ranges from 50 (faster heating) to 75% (slower heating) ethanol by volume
depending on how fast heat was supplied per unit time during the distillation process.
Redistillation using the same still increases the ethanol concentration to 90% by volume.
Fuel-grade or anhydrous ethanol, however, requires 99% purity. No matter how many times
re-distillation is repeated, however, can produce ethanol beyond 95-96% purity as water
molecules form an azeotrophic bonds with ethanol molecules. Nevertheless, to bring ethanol
purity closer to fuel grade standards, a still capable of producing 95% ethanol purity is
currently being constructed. The remaining 5% water can be removed using molecular
sieves like zeolite 3A.
Pressing problems encountered are the inability to purchase vital equipment due to
the lack of allocation for equipment outlay and the delay of the release of the 2010 fund
balance (P465,000) together with the promised 1M funding support for 2011 Biomass
Project budget from AFMA-RDEB.
In as much as the project is already in the second semester, assistance in facilitating
the release of much delayed funds (including capital outlay allocation) is humbly requested.
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Introduction
The Coconut-Based Ethanol Project (CocoEthanol) was conceptualized to
adapt and fine tune existing ethanol production technologies. In the process, it is
envisioned that newer technologies suited to Philippine conditions will be generated
to help utilize every available coconut-based feedstocks for bioethanol production.
The project was first proposed in 2009 with the aim of helping farmers improve their
income and at the same time complementing the Biofuels program of the
government. Unfortunately, the original proposal Biofuels production from coconut
lignocellulosic biomass which calls for the use of 2nd generation bioethanol
technology i.e., using sugars derived from lignocellulosic materials from plants to
produce ethanol failed to get any funding support either from PCA or from other
funding institutions. Later on, the said proposal was revised and scaled down to use
first generation ethanol production technologies which are simpler and more
importantly, less costly to produce. Although the modified proposal Enzymatic
Bioethanol Production from Toddies of Different Coconut Cultivars passed the
PCAs Project Review Committee (PRC) and was subsequently endorsed for funding
consideration by the then PCA Administrator Garin to the DA Biotech Program, the
revised proposal was also unsuccessful in soliciting the much needed funding
support. It was only in the late December of 2010 when CocoEthanol Project finally
got funded internally under AFMA-RDEB funds.
The present CocoEthanol Project is designed to be implemented in two
ladder-like phases to suit with the increasing cost of equipment outlay and the
complexity of the production processes as the Project progresses from one phase to
the other. Laboratory wares, equipment, labor and technical skills generated from the
first phase will be used in the succeeding phase, thus saving valuable resources in
the process.
Phase 1. First Generation Ethanol Technology Production
The first phase is the production ethanol using age-old first
generation ethanol (sugar/starch-based) technologies. Fermentable
sugars will come from coconut toddies harvested using the
sequential coconut-toddy-nut production (SCNTP) technology so as
not to affect the nut production.
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A related study entitled Collection and Establishment of
Energy Crops Cultivated With Coconuts for Ethanol
Production is also being prepared to complement this project.
Based on literature review, the most promising energy crop
that can be cultivated with coconut is sugar palm (Arenga pinnata)
locally known as cabo negro, kaong, or kalong-kaling. Cabo negro
is reported to be a very good source of very sweet and copious
inflorescence sap. It is reported to produce 4.3L per day per spathe
(as opposed to ~2L/day for coconut) of very sweet sap which if
fermented has the potential to produce 40,000L of ethanol/hectare
per year. Other energy crops like petroleum nut tree, yakon,
cassava, etc. will likewise be evaluated for its suitability as intercrop
with coconuts.
Phase 2. Second Generation Ethanol Technology Production.
The second phase of this project calls for the use of second
generation ethanol technologies. Feedstocks to be used are
coconut biomass like fronds, dread leaves, husks, and shell.
Enzymes, acids and their combination will be used to hydrolyze this
biomass into monomeric sugar which in turn fermented into ethanol
using different fungi and bacteria.
Present Status
1. Laboratory Establishment
The repainting and refurnishing of the former VLCP laboratory is now
90% finished. It will soon serve as the CocoEthanol/Biomass Laboratory. Despite
the lacked of equipment outlay, we managed to fabricate one of the key
equipment for ethanol production ethanol distiller or still. This development
enables the project to do fermentation trials as we can now indirectly measure
the outcome of a particular fermentation trial by way of determining ethanol
recovery.
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1.1. The PCA-ZRC Dist il ler
The PCA-ZRC Distiller (Photo 1) was fabricated based on a common
pot still/reflux design often used in moonshine alcohol production. It is easy to
maintain, relatively simple to use, and cost only between P10,000- P15,000. It
can be heated with any heat source including farm residues. The PCA-ZRC
distiller was first tested last April 28, 2011 using tuba from coconut. The
distillation rate is about 20.58mL of ethanol per minute or roughly 1.2L of ethanol
per hour. Made from stainless-steel and copper, this equipment can produce both
food grade and fuel grade ethanol (with further refluxing/stripping of the first
distillate to increase ethanol purity). Depending on how fast it is heated (amount
of heat supplied per unit time), PCA-ZRC Distillers ethanol purity ranges from 50
% (faster heating) to 75% (slower heating) ethanol by volume. Re-distillation will
increase ethanol purity to 90%, 9-10% short of the required purity for fuel grade
ethanol. A better still (Photo 2) that can produces ethanol with 95% purity is
under construction. It based on the Warren still design similar to the one
proposed by the Samar Coco/Nipa Ethanol Project. It may become operational in
two weeks time. The remaining 5% water will be removed using molecular sieve
zeolite 3A.
Photo 1. PCA-ZRC portable distiller using LPG and firewood asfuel respectively.
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2. Financial Aspects
Only P465,000 of the approved P930,000 AFMA-RDEB 2010 fund
allocation for Coconut Biomass Project was released in December 22, 2010
(Attachment 1). No equipment outlay, however, was included in the said fund
release. Thus, it was apparent even from the start that purchases of needed
equipment will become a problem. Nevertheless, the process of purchasing
laboratory supplies was immediately started last January 2011. It took 3 months
for the purchasing unit of PCA-ZRC to produce the first supplies purchased. As of
June 6, 2011 the remaining fund balance is P244, 906.44 (Attachment 2) after
the purchase of several laboratory supplies and the hiring of two personnel to
help in the project.
The current balance for supplies (expense codes 760 & 765) is P95,000.
This amount, however, is not enough to cover the on-going purchases like
chemicals (approximately P143,000), other laboratory supplies for the
construction of still, and the supplies-to-equipment swap arrangement
(approximately P50,000) with Breeding and Genetics Division.
The project is likely to run out of funds in the midst of its preparation if no
additional funds will be released sooner. May we therefore request assistance in
facilitating the release of the remaining P465,000 fund allocation for 2010 and the
promised one million pesos (1M) fund allocation for 2011 under the AFMA funds.
Photo 2. Warren still.
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3. Toddy Supply
At present, 10 coconut palms are being toddy-tapped by a hired toddy-
tapper to supply the necessary feedstock for ethanol production. The hired
toddy-tapper has been instructed to use SCNTP technology. When chemical
supplies arrive, experiments will be conducted to improve the sugar-to-ethanol
conversion efficiency in coconut sap like the use of sodium metabisulfite to
prevent spontaneous fermentation during collection and the introduction of
Saccharomyces cerevisiaein the collected coconut sap.
As supplementary source of sweet toddy,
several Cabo negro palms inside the Center were
identified for toddy-tapping. Cabo negro
inflorescences produces large amount of sweet sap
(900 1600 liters/tree/year with sugar content of 15-
20%), and if fermented, about 40, 000 liters
bioethanol per hectare per year can be produced
(Widodo, Elita, and Asari, 2010).
Photo 4. Sugar palm bunches are being harvested for seed production (inside PCA-ZRC).
Cabo negro tolerates low lighting conditions and may be a good intercrop
under coconuts. To evaluate its feasibility, a total of 500 cabo negro wildlings
(Photo 5, left side) and were put in polybags at the nursery last April, 2010. High
mortality rates, however, were observed after 2 months in the nursery (Photo 5,
right side). Transplanting stress and fungi infestation were speculated to be the
Photo3.Cabonegroinflorescencesap.
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Photo 6. Vino de Coco (70 Proof).
cause of high mortality rate. To avoid such problem, matured cabo negro seeds
were collected and will soon be germinated directly in prepared polybags.
Photo 5. Transplanted sugar palm wildlings polybagged for nursery care, newly
transplanted (left) and after 2 months (right).
4. CocoEthanol Application Studies
4.1. Economics
Recovery rate of ethanol from tuba (1 day-old) is about 9% i.e., 1.4L of
cocoethanol (50% ethanol by volume) from 15 liters of tuba. If the cost of tuba is P6.25/L
(P25/gal), the cost of ethanol produce is P92 /L (including P35 LPG cost) or P67/L if the
fuel cost is neglected (ordinary firewood). The production price is still high at this point.
However, with further refinement of the equipment, procedures (collection, fermentation,
and distillation), the cost of production may still be lowered.
4.2 Vino de Coco
One of the possible and probably the most profitable
use of ethanol is alcoholic beverage as evidenced by the
thriving industry in Quezon and Laguna provinces.
The feasibility of using ethanol produced from
distilling tuba was demonstrated by diluting it with distilled
water to 35% ethanol by volume (70 Proof). The resulting
alcoholic beverage was initially daubed as Vino de Coco.
Based on computations in section 4.1, one liter of 50% (priced
at P67/L) will become 1.428L of 35% ethanol by volume when
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Photo 7. Ethanol being tested askerosene substitute.
Photo 8. Coconutwater(~23%fermentablesugar)from
maturedcoconutscollectedforfermentationand subsequentdistillationatPCAZRC.
diluted. Rough estimates of the production price of Vino de Coco is P46.92/L (excluding
bottling and overhead costs)
4.3 Other uses
Preparations are being undertaken to test the use of
CocoEthanol on various household fuel requirements. These
include the use of cocoethanol to substitute kerosene in
petromax and kerosene stoves. Initial trials using hydrous
ethanol (90% ethanol by volume) encountered problems of
lack of appropriate heat to cause the mantle to glow in the
case of petromax and uneven flame in the kerosene stove.
Additional trials will be conducted once we can
produce anhydrous ethanol. Likewise, several blend ratios with
kerosene will also be tested in the future.
5. Exploration of other sources of ethanol
5.1 Ethanol from Cocowater
The feasibility of producing ethanol from coconut water was evaluated upon the
suggestion of Mr. Bonifacio B. Pangahas, Chairman of PRC when he visited the Center
last week.
Coconut water was collected from
mature coconuts. Mother liquor or natural
tuba yeast cells were collected from 1-day
old tuba that settles at the bottom of the
container. Incorporation of tungog(tangal)
and pH adjustment were the additional
treatments used.
As expected, only a small amount
of ethanol can be recovered from fermented
coconut water, ranging from 0.43% to
0.98% (Table 1). These results are consistent with the theoretical ethanol potential of
coconut water of roughly 1.28% (one half of the total fermentable sugar present). Total
sugars in coconut water from mature nuts averages only about 2.56% (Banzon and
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Amount Fermentation ETOH
Fermented Time(days) mL (%) Purity1 15L 1 w/tungog,pHadjtdto4.3 66 0.43 nottested*2 15L 2 WITHOUTTungog 120 0.77 nottested*3 15L 2 with25gtungog 150 0.98 nottested*3 15L 2 with25gtungog 130 0.84
nottested
*
3 15L 3 with25gtungog 116 0.68 nottested*
TrialETOHRecovery
Treatments
Velasco 1982 citing Sison, 1977). The difference of 0.30 (a very small amount) between
the theoretical and actual recovery values can be attributed to the incomplete
fermentation of available sugars and the losses during distillation. Adding molasses or
concentrating the sugar content in coconut water by reverse osmosis was proposed by
Banzon and Velasco (1982). However, such processes require additional cost and the
resulting product may not be worth the effort and the money invested.
Table 1. Preliminary trials on the potential of coconut water from matured nuts as a feedstock forethanol production.
*not enough samples to test purity of distillates using existing hydrometer.
6. Future Plans And Proposals Related To CocoEthanol Project
6.1 Pilot testing of a village-level cocoethanol production system
A proposal is being prepared to request the assistance of PCA to pilot
test a village-level cocoethanol production system in selected coconut cluster
communities in the country (Cartoon 1). Under this proposed scheme, several
PCA-ZRC distilling apparatus will be distributed to coconut farmers at a cost
(subsidized price or soft loan scheme with ethanol produced as payment).
Redistillation/ethanol drying to anhydrous ethanol (99% purity) will be done at the
barangay buying station. Selling of anhydrous or fuel-grade ethanol to oil
companies or to local buyers will be the responsibility of each cluster with the
assistance of PCA.
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Farmer4Tuba
production
&
Distillationto75%
Ethanolbyvolume
Farmer3Tuba
production
&
Distillationto75%
Ethanolbyvolume
Farmer1Tubaproduction&
Distillationto75%
Ethanolbyvolume
BarangaySCFOEthanol
BuyingStation(Redistillationto
99%ethanolby
volume)
Farmer5Tubaproduction
&Distillationto
75%Ethanolby
volume
Farmer2Tubaproduction
&Distillationto
75%Ethanolby
volume
BUYERAnhydrous/Fuel
GradeEthanol
(99%Ethanolby
volume
Cartoon 1. Proposed CocoEthanol village-level production system.
6.2. Exploration of other Energy Crops
6.2.1 Collection and Establishment of Energy Crops Cultivated With Coconutsfor Bioethanol Production
Preliminary preparations were undertaken to establish a collection of
energy crops that can be cultivated with coconuts in order to quickly evaluate its
potential and to produce proof-of-concept often required by funding institutions.
6.2.1.1Sugar palm/Cabo negro (Arenga pinnata)
Cabo negro palm is endemic to the Philippines and in other countries in
Southeast Asia. Agroforestry database (Orwa et al.2009) describes cabo negro
as a monoecious palm (separate male and female flowers) with solitary,
unbranched trunk (30-40cm in diameter). Its height reaches to about 15-20m. Its
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leaves are pinnate, and leaf sheaths with numerous black hairs cover the stem.
Flowering occurs as early as 5-6 years to as late as 10-12 years old, starting from
the top and ends near the base of the trunk. The flowering stage covers a 4-6
year period. Cabo negro reaches maturity at 15 years old. Although rarely
cultivated, immature fruits are harvested from the wild for its seeds and
processed for culinary condiments known as kaong. It is classified as non-timber
forest products and is sporadically found in clusters along riverbanks and in log-
over areas.
6.2.1.2 Petroleum nut tree or Hanga (Pittosporum resineferum)
Arrangement has been made for the Department of Agriculture - La Paz
Experiment Station in La Paz, Zamboanga City for them to provide PCA-ZRC with
grafted Petroleum nut tree at P15 piece (Photo 9).
Photo 9. Petroleum nut tree or Hanga (Pittosporum resineferum)at DA Experimental Station, La Paz, Zamboanga City.
6.2.1.3 Ycon (Smallanthus sochitolius)
Ycon (Smallanthus sochitolius) is an exotic plant from Peru. It produces
tuber roots that have a lot of stored sugars which can be fermented to ethanol.
Arrangement has been made for a joint study with DA La Paz Experimental
Station to plant yacon under coconuts (Photo 10).
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Photo 10. Ycon (Smallanthus sochitolius) at the DAExperimental Station, La Paz, Zamboanga City.
7. Cocoweek 2011 and 1stPhilippine Biofuels Conference
We intend to showcase a simple ethanol distillation set-up using tuba as
feedstock in the coming Cocoweek 2011 and, if possible, at the 1 st Biofuels
Conference in August of 2011.
8. Literature Cited
Banzon, J.A. and J.R. Velasco. 1982. Coconut. Production and Utilization.Philippine Coconut Research and Development Foundation, Inc.(PCRDF). Amber Avenue, Pasig, Metro Manila.
Elberson, W and Oyen, L. 2010. Sugar palm (Arenga pinnata) Potential of sugarpalm for bio-ethanol production. Translated from Nieuwe grondstoffenvoor biobrandstoffen alternatieve 1e generatie energiegewassen.FACT Foundation. Wageningen University
Orwa C, Mutua A , Kindt R , Jamnadass R, Simons A. 2009. AgroforestryDatabase: a tree reference and selection guide version 4.0(http://www.worldagroforestry.org/af/treedb/)
WidodoT.W., Elita R., and A. Asari . 2010. Sugar Palm (Arenga pinnataMerr)Plantation for Bioethanol Production, Sustainable
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Attachment 1
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Attachment 2
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PROPOSED BUDGET
Program Title: Biofuel production from coconut lignocellusic biomass
Project Title: Utilization of Coconut Lignocellulosic Biomass For Bioethanol Production. Phase 1. Coconut toddy and starch-based ethanol.
Acc ount
Code June July August September October November
I. Personal Services
A. Direct Cost
1. Salaries
2. Wages
Laboratory Aid @ P300/day 795 6,600.00 6,600.00 6,600.00 6,600.00 6,600.00 6,600.00
General Services 795 25,000.00 25,000.00 25,000.00 25,000.00 25,000.00 25,000.00
II. Maintenance and Operating Expenses
A. Direct Cost
1. Traveling ExpenseLocal 751 15,000.00 15,000.00 15,000.00 15,000.00 15,000.00 15,000.00
2. Supplies and Materials
Office Supplies 755 5,000.00 5,000.00 5,000.00 5,000.00 5,000.00 5,000.00
Laboratory Supplies 760-2 500,000.00
760-3 500,000.00
Telephone - Mobile 773 1,000.00 1,000.00 1,000.00 1,000.00 1,000.00 1,000.00
Postage and Deliveries 771 1,000.00 1,000.00 1,000.00 1,000.00 1,000.00 1,000.00
4. Training and Seminar 753 50,000.00
5. Membership Dues 778 30,000.00
6. Publication 780 50,000.00
7. Meetings and Conferences 969-3 20,000.00
8. Magazine and subscriptions 786 25,000.00
Sub-total
3. Communication
Grand Total
Monthly
Salary
Attachment 3
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Attachment 4
Work and Financial Plans for 2011
Coconut Biomass Utilization
Work and Financial Plan for 2011
PROGRAM/PROJECT/
ACTIVITIES
Q1 Q2 Q3 Q4
A. Biofu el/Bio -energ y
Development
Repair of VLCP bldg for
bioethanol laboraory use
1set
Lab glasswares and
laboratory equipment
1 set
Distilling Apparatus 1 unit each
Fermentation vat 1 unit
Ethanol fermentation trials
Established toddy and
starch based
fermentation/distillation
Fermentation/d
istillation
proces
1 protocol
developed
Development of low-emission
and low cost biomass charcoal
kiln for small farms and villages
Low-emission biomass
charcoal kiln
Design and
construction
of kiln
Design and
construction of
kiln
Design and
construction of
kiln
Testing of
charcoal kiln
1kiln
constructed/
established
50
Emission test apparatus/ Acquisition of
test
apparatus
Acquisition of test
apparatus
Testing of
emission
apparatus
Methods of
test on
emission
establsihed
Emission test
apparatus
acquired and
tested
100
Data on coco-biomass
charcoal emission
Emission
Testing/data
gathering
Emission
Testing/data
gathering
Emmission
gases
characterized
50
Solid Bio -fuel: Charcoal and
briquette, activated carbon from
coconut biomass studies
Production of charocal
and briquette, activated
carbon manufacture for
revenue generation
Design of
charcoal kiln
and
briquetting
machine
Construction of
charcoal kiln and
briquetting
machine
Charcoal and
briquette,
activated
carbon
manufacture
/testing
Charcoal and
briquette,
activated
carbon
manufacture
/testing
1
Recommendati
on for revenue
generation 100
Use of coir-basedbioengineering technologies for
climate change mitigation
Data on soil erosionrates in vulnerable areas
where bioengering
technologies are studied
1 twinning,looming
machines
1 stichingmachine
transferred from
DRC
Evaluation/analysis of data Performancereport/data on
bioengineering
technologies 250
B. Biomass Composite
Development
Binderless composite piloting Pilot trials for
Binderless boards
Acquisition of
hydraulic hot
press
Establishment
of Pilot plant
Pilot testing 1 Pilot plant
established
200
CFB products enhancement Improved physical,
mechanical properties of
CFB
Product
improvement
trials on weight
and density
Product
improvement
trials on weight
and density
Improvement
on surface
quality
Improved at
least 2
properties of
CFB
50
Coir-plastic composite
Extruder, Hot press, coir-
plastic composite
manufacture
Acquisition/install
ation of
equipment
Acquisition/inst
allation of
equipment
testing on
manufacture of
fiber-plastic
compositeusing
established
Developed I
technology on
fiber-plastic
composite
150
Paper and paperboard
New products from
coconut paper
introduced and
disseminated the
technology
Introduced
new paper
products and
imrpoved
paper-making
facilities
Production of
paper and
paperboard
Production of
paper and
paperboard
Production of
paper and
paperboard
Conduct of
training for
technology
dissemination
50
TOTAL 2,531
Characteri zation of greenhouse
gases emission from coconut
biomass carbonization process
Acquisition/Fabrication of Lab
Equipment and machineries
procurement of
lab wares
installation/
testing of lab
wares
installation/
testing of lab
wares1581
PROJECT TITLE: COCONUT-BASED BIOMASS UTILIZATION
KEY RESULT AREA PERFORMANCE
INDICATOR
QUARTERLY TARGETS (CY 2011) TOTAL FOR
THE YEAR
2011
BUDGET
ALLOCATION
(PhP'000)