renewable energy from oil palm

Renewable Energy from Oil Palm

Academician Tan Sri Datuk Dr. Augustine S.H. Ong27 November 2006

Oil Palm Plantation

Plantation

Palm Tree

Fresh Fruit Bunch

National Energy Demand

Year

National Energy Demand

(MW)

Electricity Generated by Palm Oil Mills

(kWh)

12,000 2.64 million

Electricity Generated by Palm Oil Mills

(MW)

2005 301

Source: Ir. Ravi Menon (2006)

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.

Biomass from Palm Oil Mills in 2005

Biomass Quantity (‘000 000)

Empty fruit bunches (EFB) 19.5 tonnes

Palm Fibre 11.9 tonnesPalm Shell 5.9 tonnesPalm Oil Mill Effluent (POME) 51.6 m3

Empty Fruit Bunches –19.5 million tonnes in 2005

Palm Fibre – 11.9 million tonnes in 2005

Palm Shell – 5.9 million tonnes in 2005

Palm Shell and Fibre as Boiler Fuel

Energy Database for Palm Biomass

SampleCalorific Value (kJ/kg)

Ash (%)

Volatile Matter (%)

Moisture (%)

Hexane Extractable

(%)

EFB 18,795 4.60

6.10

Shell 20,093 3.00 83.45 12.00 3.26

15.20

87.04 67.00 11.25

Fibre 19,055 84.91 37.00 7.60

POME 16,992 77.09 93.00 12.55

Source: Chow et al. (2003)

Conventional Methods of Preparation of Methyl Esters

• Fat Splitting of Glycerides into Fatty Acids followed by Esterification.

• Base-Catalysed Transesterification of Glycerides

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.

2. Transesterification of neutral glycerides into methyl esters in the presence of base catalyst.

RCOOH + MeOH RCOOMe + H2O

CH2OCOR1

CHOCOR2

CH2OCOR3

MeOH

R1COOMe

R2COOMe

R3COOMe

CH2OH

CHOH

CH2OH

++

3000 tpy Palm Biodiesel Pilot Plant at MPOB

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.

Palm Biodiesel Pilot Plant

RBD Palm Oil Methyl Esters RBD Palm Olein Methyl Esters

Key Fuel Properties of Palm Biodiesel

Property Palm Biodiesel Malaysian Petroleum Diesel

Density at 15°C (kg/L)ASTM D4052

0.875 0.853

0.10

4.0

+15

98

Cetane NumberASTM D613

62.4 55.2

45,800

0.14

Sulfur Content (% wt)IP 242

< 0.04

Viscosity @ 40°C (cSt)ASTM D445

4.5

Pour Point (°C)ASTM D97

+15

Flash Point (°C)ASTM D93

174

Gross Heat of Combustion (kJ/kg)ASTM D2332

40,335

Conradson Carbon Residue (% wt)ASTM D198

0.02

Exhaustive Field Trials using Palm Biodiesel

• Successfully conducted between 1986 – 1994 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.

Field Trials using Various Diesel Engines

Field Trials using Mercedes Benz (OM352) Diesel Engines Mounted on Passenger Buses

(each bus covered 300,000 km)

On The Road with Palm Biodiesel

KUALA LUMPURKUALA LUMPUR

ULU PAKAULU PAKA

KLUANGKLUANG

K.LUMPURK.LUMPUR

CHERASCHERASK.SELANGORK.SELANGOR

TANJONG MALIMTANJONG MALIM

PAJEROPAJEROLEN OMNIBUSLEN OMNIBUSSELANGOR OMNIBUSSELANGOR OMNIBUSTOONG FOONG OMNIBUSTOONG FOONG OMNIBUS

Smoke Emission from Passenger Bus using Petroleum Diesel

Clean Smoke Emission from Passenger Bus using Palm Biodiesel

Emission Test of Palm Diesel and Blends of Palm Biodiesel / Petroleum Diesel

73.7

60.6 57.8

24.2

0

20

40

60

80

100

HC SMOKE

Blend of 50% petroleum diesel/50%Palm Biodiesel)100% Palm Biodiesel

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, CO2, SO2 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)

(cont’)

Summary of Field Trial

• Palm diesel : higher flash point (174oC c.f. 98oC 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).

Recent Trials using Palm Diesel on Commercial Trains

• Trials conducted by Prignitzer Eisenbahn (PE) Arriva in Germany, since September 2004.

Summary of Field Trials(Commercial Trains)

No problem concerning carbonNo deposit in combustion chamberNo changes in motor oilNo problem with materials in fuel system

Phytonutrients: Opportunities

Value-Added Products

For every 1 tonne of methyl esters burnt as fuel, we also burn away:

0.6 kg Carotenoids0.8 kg Vitamin E0.5 kg Phytosterols0.4 kg Squalene0.05 kg Coenzyme Q0.06 kg Phospholipids


The values of the phytonutrients are:

Carotenoids (30%) US300/kgVitamin E (50%) US500/kgPhytosterols (Industrial Grade) US25/kg

(as β−sitosterol)Squalene (Nutraceutical Grade) US33/kgCoenzyme Q (Pharmaceutical Grade) US2,800/kgPhospholipids (Nutraceutical Grade) US25/kg


For every 1 tonne of methyl esters burnt as fuel, the value of phytonutrients burnt away is:

~US 970/tonne(RM 3,686/tonne)

Production of Phytonutrients from Palm Diesel using

MPOB Technologies

CPO Methyl Esters(Palm Diesel)

Distillation

Phytonutrients Concentrate Containing Carotenes, Tocols,

Phospholipids (Lecithin), Sterols, Coenzyme Q and

Squalene

Crude Palm Oil ( CPO )

Distilled MethylEsters

(Palm Diesel)

CarotenesTocolsSterols

SqualeneCoenzyme Q

Phospholipids(Lecithin)

Feedstock for value-added oleochemical

products

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

+ +

Development of Low Pour Point Palm Biodiesel

Low Pour Point Palm Biodiesel

Palm Biodiesel(Crude / Distilled Palm

Oil Methyl Esters)

Seasonal Pour Point Requirement of Biodiesel

Autumn

Winter

Summer

Spring

Season Pour Point (°C)

Spring -10

Summer 0

Autumn -10

Winter -20

PropertyNormal

Palm BiodieselLow Pour Point Palm Biodiesel

Petroleum Diesel

Density at 15°C (kg/L)ASTM D4052

0.875 0.882 0.853

0.10

4.0

+15

98

Cetane NumberASTM D613

62.4 57 55.2

45,800

0.14

Sulfur Content (% wt)IP 242

< 0.04 < 0.04

Viscosity @ 40°C (cSt)ASTM D445

4.5 4.5

Pour Point (°C)ASTM D97

+15 -21

Flash Point (°C)ASTM D93

174 153

Gross Heat of Combustion (kJ/kg) ASTM D2332 40,335 39,160

Conradson Carbon Residue (% wt) ASTM D198 0.02 0.01

Key Fuel Characteristics of Normal Palm Biodiesel and Low Pour Point Palm Biodiesel

Fuel Properties of Palm Biodiesel vis-à-vis EN14214 & ASTM D6751

EN 14214 ASTM D6751

Min Max Min Max

Ester Content % mass 96.5 - - - 98.5

-

1.9

130

-

-

47.0

-

-

Density at 15°C g/cm3 0.860 0.900 - 0.8783

Viscosity at 40 °C cSt 3.5 5.0 6.0

-

0.0015

0.05

-

-

3

4.415

Flash Point °C 120 - 182

Cetane Number - 51.0 - 62.4

Oxidative Stability, 110°C hours 6.0 - >6

Copper Strip Corrosion(3h at 50 °C)

rating 1 - 1a

Sulphur Content % mass - 0.001 <0.001

Carbon Residue (on 10% distillation residue)

% mass - 0.3 0.02

Palm BiodieselProperties Unit

EN14214: European Standard for Biodiesel ASTMD6751: Standard Specification for Biodiesel Fuel (B100) Blend Stock for Distillate Fuels


EN 14214 ASTM D6751

Min Max

Pour Point °C Report Report 15

-

-

-

-

-

-

Palm Biodiesel

0.02

0.05

0.8

-

-

-

Acid Value mg KOH/g - 0.5 0.08

Iodine Value - - 120 52

Content of LinolenicAcid Methyl Esters % (m/m) - 12 <0.5

Content of Polyunsaturated Methyl Esters (more than 3 double bonds)

% (m/m) - 1 <0.1

Properties UnitMin Max

Sulphated Ash Content % mass - 0.02 <0.01

Basic Sediment and Water % mass - 0.05 <0.05



EN 14214 ASTM D6751

Min Max

-

-

-

-

-

-

Palm Biodiesel

Methanol Content % (m/m) - 0.2 - <0.2

-

-

-

0.02

0.24

Monoglycerides % (m/m) - 0.8 <0.4

Diglycerides % (m/m) - 0.2 <0.2

Triglycerides % (m/m) - 0.2 <0.1

Free Glycerol % (m/m) - 0.02 <0.01

Total Glycerol % (m/m) - 0.25 <0.01

Properties UnitMin Max


Environmental Impact of Palm Biodiesel

• Environment-friendly – great reduction in CO2, CO, total unburnt hydrocarbon, SO2, 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.

Production and Consumption of Palm Biodiesel: A Closed Carbon Cycle

Carbon Dioxide Emission

Palm Biodiesel

Vehicles Consumption

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

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

MPOB-LIPOCHEM Biodiesel PlantFeedstock 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 55 56 min.

Melting Point (AOCS Cc-25) (°C) 33 to 39 24

Colour(5 ¼” Lovibond Cell) 3 Red max. 3 Red max.

Note: RBD – refined, bleached and deodorized

3D Plant Layout for Low Pour Point Palm Biodiesel Plant

(based on 30,000 tpy feedstock)

Indicative Costs for the Production of Normal Palm Biodiesel in Malaysia

Capital Cost: 10,000 tonnes per year – USD 4 million60,000 tonnes per year – USD 12 million

Cost (USD) per tonne Biodiesel Ex-FactoryMedium Sized Plant

USDRefined Feedstock Costs 400Processing Costs 70Depreciation 40By-Product Credit – 20

Cost USD/tonne Ex-Factory 490

Cost EUR/litre Ex-Factory 0.36

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

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

Indicative Costs for the Production of Low Pour Point Palm Biodiesel in Malaysia

Capital Cost: 30,000 tonnes per year – USD 3.5 million

USDFeedstock Costs 490Processing Costs 40Depreciation 10

Cost USD/tonne Ex-Factory 540to Importing Country

Cost EUR/litre Ex-Factory 0.40

Selling PriceLow 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

Potential Renewable Energy being Developed

Biogas from Palm Oil Mill Effluent (POME)

• Biogas (65% CH4, 35% CO2) – gaseous product from anaerobic digestion of POME

• About 28 m3 per tonne of POME treated

• Calorific value – 4740 kcal/m3

• Ready gaseous fuel for gas engine, boiler and burner

• A potential 5th fuel source in SREP

Biogas

• Product from Anaerobic Digestion of POME• Good Energy Resource but Untapped

Some Properties of Gaseous Fuels

Properties Biogas Natural gas

Liquefied Petroleum

Gas Gross calorific value (kJ/Nm3) 19,908 – 25,830 3,797 100,500

Specific gravity 0.847 – 1.002 0.584 1.5

Ignition temperature (°C) 650 – 750 650 – 750 450 – 500

Inflammable limits (%) 7.5 – 21 5 – 15 2 – 10

Combustion air required (m3/m3) 9.6 9.6 13.8

Source: Quah and Gillies (1981)

Fischer-Tropsch Process

The original chemical equation:(2n + 1) H2 + nCO CnH2n+n + nH2O

The initial products (i.e. CO and H2) can be produced by:(1) Combustion of methane:

CH4 + ½ CO2 2H2 + CO

(2) Gasification of coal or biomassCH + ½ O2 ½ H2 + CO

Pilot Plant Unit for the Production of Bioethanol from Cellulosic Biomass Source

National Renewable Energy Laboratory (NREL) in Golden, Colorado

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

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.

THANK YOU

renewable energy from oil palm

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