Converting Palm Waste to WealthConverting Palm Waste to …poic.com.my/files/palmex/P1.pdf · Special Features of Digester Tank BELL Eco Power Sdn. Bhd. Digester Tanks Comparison

Liana Low

CEO

BELL Group of Companies

28 July 2011

Sabah Hotel, Sandakan

Malaysia

Liana Low

CEO

BELL Group of Companies

28 July 2011

Sabah Hotel, Sandakan

Malaysia

Converting Palm Waste to WealthConverting Palm Waste to Wealth

“ Rediscover Renewable Energy In The Palm Oil

Industry To Create A Green Economy”

INTRODUCTION

• Malaysia is blessed to have a successful & progress ive palm oil industry.

• Year after year, our country & businesses are bene fiting tremendously from this industry.

• We have been benefiting from upstream to downstream . From plantation to oleo chemical. But, that is o nly part of the story of this industry.

• The real hidden treasures of the industry is in th e liquid & solid biomass waste products after processing.

• In our attempts to find solutions to environmenta l problems that are linked to this industry & to work together with international organization on global climate change, we have pushed beyond our industr y boundary to be able to achieve zero waste & zero carbon.

.

• With Energy Technology, we can recapture & reuse energy & able to achieve efficient energy conversion chain with all the renewable waste resources in the palm oil industry improving the budget & the bottom -line.

• We can change the way the world think about the was te in the palm oil industry – as the waste is not garba ge but commercially viable & renewable resources.

• In the process, we have found hidden treasures to develop a roadmap from waste to wealth.

• Today, on behalf of BELL Group, I would like to sha re with you on some of the many treasures that has brought us from an Independent Palm Oil Miller to an Independent Power Producer, a more high-margin product from the renewable waste of the palm oil milling industry.

MONETIZE ENERGY TECHNOLOGY

Corporate Metamorphosis

Independent Palm Oil Miller

Green Independent Power Producer

Moving towards

Fully use of Waste from Palm Oil MillFully use of Waste from Palm Oil Mill

How does it happen ??How does it happen ??

ENERGY PROVIDER

Palm Shell

EFB Fibre

Pressed fibre

POMEPOME

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• The liquid & solid biomass waste can be used as a consistent non-contaminated feedstock for both Biog as & Biomass Green Power Plants.

• Palm Oil Mills can be transformed into Green Independent Power Plants & operate as Centre of Ene rgy Efficiency .

• Palm Oil Biogas & Biomass power generation is here to be tapped. It is right at our door steps. It is ec o-friendly, intelligent & a smarter way to contribute to the international effort in improving the environment & to create a green economy. Thus, giving a superb ima ge to the Palm Oil industry.

• Currently, 98% of conventional POMs is operating und er Energy Inefficiency. Logically, we should monetize the energy technology to improve energy generation or conversion efficiency, whether it is heat or electr icity.

GREEN ELECTRICITY FROMPALMBASED LIQUID & SOLID WASTE

How can we be more efficient?

• Manage energy demand efficiently • Better use of co-generation• Efficient Power Plant Boilers & Steam Turbines• Efficient industrial process design & operation• Use of energy efficient motors & variable speed dri ves• Automation System for all Operating Stations• SCADA (Supervisory Control & Data Acquisition) Sys tem• ERP (Enterprise Resource Planning) System• Once fully automated, Palm Oil Mills are able to en gage

skilled workers like engineers & technicians rather than manual workers.

NB: (Oil Palm Plantation Sector will face chronic labor problems caused by limit on immigrant plantation labor, which will be a serious long term impact to the Palm Oil Industry).

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Re-engineering Palm Oil Mill towards a High-technol ogy Driven Enterprise with Air-Conditional Push-Button Operati on Control Rooms. This will greatly reduce the dependency on low-skilled foreign workers like cleaning up the effluent ponds .

BELL’s First SREP Model(BELL Eco Power Sdn. Bhd.)

BIOGASCombined Heat & Power Cycle

2 MW Green Power PlantBATU PAHAT, JOHOR

Biogas Power Plant : 2 MW

CER : 35,000 per annum

The entrapment of Methane from POME is not only a source of renewable energy but we are also minimiz ing the release of harmful gases to the environment.

Biogas produced from the organic liquid biomass in the Palm Oil Mills can be utilized for green electricit y generation, boiler combustion or combustion in the flare for emission reduction.

BELL Eco Power Sdn. Bhd.


• Malaysia First CDM Based Biogas Grid Connected Rene wable Energy Power Plant.• Malaysia First RE Power Project to Inject Green Ele ctricity to TNB Open Ring System.• Malaysia First to Incorporated SMART Technology int o the Cabling System that is

Unique, Safe & Reliability that Compliance the Requ irement of TNB for Power Injectioninto TNB Open Ring System.

• Malaysia First Green Independent Power Producer wit h Combined one unit 2 MWBiogas & one unit 10 MW Biomass Independent Power Plants to decarbonize theNational Grid.

BELL Eco Power Sdn. Bhd.Biogas Renewable Energy System

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Installation of New Glass-fused-Steel Tank in Progress

Existing Mild-Steel Tanks

Special Features of Digester TankSpecial Features of Digester Tank


Digester Tanks ComparisonGLASS FUSED TO STEEL MILD STEEL

BIOTANQ® structures are engineered with a predicted minimum 30 year design life in accordance with the

requirements of ISO 15686 Part 1, & incorporate the relevant international

design standards.

The life span of the mild steel tank is very much dependant on the

application & the process environment. Most mild steel digester will operate

for 10-15 years.

The BIOTANQ® tanks can be coated to suit the pH range of 1-14. With the corrosion resistance of the glass

application the waste/gas is not in contact with the steel.

There is no corrosion protection for the mild steel tanks & the waste/gas will be in contact with the tank walls.

The installation of a 4000m³ tank will take approx 12-14 days to complete the

build.

The installation of the mild steel tank 4000m³ will take approx 1 month.

Foundation & Concrete Base for Glass Tank

PilingPiling Foundation Foundation

Erection of 1st ringErection of 1st ringInstall nozzles & flangesInstall nozzles & flangesSetting & Setting & leveling jacksleveling jacks

Digester Tanks Comparison

For the installation of the Glass Fused to Steel tanks, the works are carried out at ground level with the use of specialised Jack equipment.

Therefore, from a Safety aspect, no work is carried out at height.

The welded mild steel tank is constructed from the ground upwards & therefore the last ring of the tank is install at approx 12m above the ground, having a requirement for workers, tools, equipment & materials to be at height increasing the risk of hazards & accidents.

Installed on the BIOTANQ® digester tanks will be our BIODOME® double membrane gas holders having a storage volume of 810m³.

From a calculation of the mild steel tank with 22.2m diameter & 1 m high roof

the gas volume would be 129m³

Calculation, V = ⅓ ( π x r 2 x h )

The BIODOME gas holder will provide a constant pressure output of 8bar for the use with the gas engines, regardless of the volume of gas within the BIODOME there will be an output under pressure.

The fixed mild steel roof will only allow gas to be withdrawn under pressure when the roof space is full; once the

volume within the roof is reduced the pressure is lost & therefore gas

to be drawn out with the use of a pump which creating potential

vacuum situation.

GLASS FUSED TO STEEL MILD STEEL

Glass Tank & Gas Biodome Installation

1st ring being jacked1st ring being jacked

Assembly by using Assembly by using bolts & nutsbolts & nuts

2nd ring being jacked2nd ring being jacked

Before inflation of Before inflation of membranemembrane

Completed TankCompleted Tank Inflated membrane

Function & Systemic Flow of Venturi Mixer

Chopper Pump

POME

Biogas

Membrane

Air pipe

Glass fused wall

Chopper pump draws POME from tank,

pumps it to ventury chamber.

POME Recirculation with Gas Injection

Chopper Pump

POME

Biogas

Membrane

Air pipe

Glass fused wall

Biogas is aspirated through air pipe,

mix with POME and injected into the tank.

Special features – Gas Mixer System

�3-Dimensional mixing pattern eliminates formation of surface scum

�Higher efficiency �Clog-free operation


No equipment

inside the tank


Easy maintenance accessible

from outside the tank

Flow Diagram of Biogas Digester System

POMEFrom CPO Mill

Oil Trapping Tank

Digested Effluent To

Aerobic Ponds

Solids to Fields(Disposal)

Electricity415 v / 11kv

Biogas Tank Digester

Blower Fan Desulphurizationunit Biogas Engine Room

Flaring Stack

B E L L

BIOGAS POWER PLANT

Use Biogas as Green Electricity Generation for Palm Oil Milling Process and Connecting to National Grid .

POME

BIOGAS


DECARBONING ELECTRICITY GRID

EXHAUST FOR HEATING

Post-Treatment

• Digestate– Liquid fertilizer (store & spread)– Cake (dewater, store & spread)

• Gas– Treatment depends on use (de-humidify,

CO2 extraction)

POME as a Potential Option towards Solving Electricity & Gas Supply.From organic liquid biomass to cleaner air:

• Biogas has the great advantage to being produced lo cally. It can be used as high quality gas for industry & s upplementgas pipeline & also as fuel for vehicles.

• A path to reliable energy at a modest cost for rura l electrification in providing electricity to village s, homes, schools, farms & cottage industries as well as bein g used for telecommunication, water supply & irrigation.

• Possible to purify Biogas to Biomethane (CBG).

• Compressed biomethane is similar in composition to C NG (Compressed Natural Gas) which has no negative impa ct on the environment.

POTENTIAL VALUES OF BIOMETHANE

• Suitable to power public service vehicles, coaches, taxis, passenger cars & even trains.

• Biomethane can be fed directly into the gas grid net work to de-carbonize the national gas grid.

• Where it is not possible to generate biogas natural ly, we can take CBG (Compressed BioGas) from the production si te, which was compressed, stored & dispense it in the same way in different vicinity.

• Many so-called “biofuels” – such as biodiesel & bioet hanol –have driven up food prices. However, this is not so with palmbased biogas, as it is generated entirely from liquid waste material. Hen ce, it has no impact on the food chain – in contrast to land ta ke-up for crop-based biofuel.

POME as a potential option towards solving electricity supply.

Based on Palm Oil Production Statistic in year 2010 ,• CPO Production = 17 million Mtons• FFB equivalent (x 5) = 85 million Mtons• 1 Mton FFB generate = 45 Kw of power• 85.00 million x 45 Kw = 3,825 Gw per year

If we were to utilize the biomass like shells, EFBs & Mesocarp Fibre, we will achieve another 16,000 Gwper year.

From the contribution of Palmbased Biogas & Biomass power generation of about 19,825 Gw, we will be abl e to supplement energy needs in our country.

Combined GFS DigesterWith BIODOME Roof.San Miguel FoodsVIETNAM

Combined GFS DigesterWith BIODOME Roof.

Palm Oil Effluent DigestionMALAYSIA

High Technology Tanks & Gas Bladders

12,600m3 BIODOMEBiogas Plant, Denmark

540m3 BIODOMEEmery Oleo-Chemical,

Klang, Malaysia

Free Standing Aesthetic Gas Holders

1,580m3 BIODOMEJangsoogun, South Korea

340m3 BIODOMEBoseong, South Korea

Free Standing Aesthetic Gas Holders

Project Track Records by Biodome Asia within the Region (2009 – 2010)

Country Description Year

South Korea 1-off BIODOME ground mounted double membrane gas holder with a volume of 1150m³ 2010

Malaysia 6-off 4000m³ digesters complete with top mounted BIODOME gas holders. 2010

Fiji 1-off BIODOME ground mounted double membrane gas holders with a volume of 660m³ 2010

Malaysia/Sabah 4-off 4000m³ digesters and 1-off secondary digester complete with

R/C settlement tank

2010

Malaysia 2-off 4000m³ digesters complete with top mounted BIODOME gas holders. 2009/2010

Vietnam 2-off 4700m³ digesters complete with top mounted BIODOME gas holders. 2010

Vietnam 2-off 4700m³ secondary digester tanks open topped. 2010

Philippines 1-off 4700m³ digesters complete with top mounted BIODOME gas holders. 2010

Philippines 1-off 4700m³ secondary digester tanks open topped. 2010

South Korea 2-off BIODOME ground mounted double membrane gas holders with a volume of 260m³ 2010

South Korea 1-off BIODOME ground mounted double membrane gas holders with a volume of 340m³ 2009

BELL’s Second SREP Model(BELL Eco Power Sdn. Bhd.)

BIOMASSElectro-Mechanical Power Generation

10 MW Green Power PlantBATU PAHAT, JOHOR

Biomass Power Plant : 11 MW

Export to the Grid : 10,000 kWh

Auxiliary Power Consumption : 1,000 kWh

CER : 54,000 per annum

Boiler becomes the most critical equipment because of the typical characteristic of lower calorific va lue, higher moisture content & the presence of more potassium & alkali chlorides in the Empty Fruit Bunches.


BELL’s Third SREP Model(BELL Green Power Sdn. Bhd.)

CO-GENERATIONCombined Heat & Power Cycle

12 MW Green Power PlantSRI LINGGA, MELAKA

“ZERO WASTE SOLUTION”in COGENERATION POWER PLANT

BOD20, SUSTAINABILITY, CDM & GREEN TOURISM

• Combined Biogas & Biomass Power Plant– High Performance & Fully Automated.

• Boiler Modification for Biogas Burner– High Energy Efficiency & Free Resources

• Steam Turbine Generator– Multi-stages High Pressure

• Waste Water Treatment Plant– High Efficient & Reliable

• CDM Investment– High End Technology for High CER Yield

BIOGAS & BIOMASS CO-GENERATION POWER PLANT

Mesocarp Fiber EFB Shell POME

Tank DigesterHigh Pressure Boiler

Extraction Condensing Turbine

National Grid

Revenue for 50 Revenue for 50 mtonmton FFB/hr mill from the sales of FFB/hr mill from the sales of 10 10 mWhmWh of electricity to TNB @ RM 0.21 per kWh of electricity to TNB @ RM 0.21 per kWh

== RM16,800,000 per yearRM16,800,000 per year

Methane Supply to Combustion Chamber

Revenue from Sales of Electricity to the GridRevenue from Sales of Electricity to the Grid(BIOGAS & BIOMASS)(BIOGAS & BIOMASS)

•• Additional revenue for a 400,000 Additional revenue for a 400,000 mtonmton FFB/ year palm oil mill would be:FFB/ year palm oil mill would be:

•• Sales of 10 Sales of 10 MWhMWh electricity @ RM 0.21 per kWh electricity @ RM 0.21 per kWh == RM16,800,000/yearRM16,800,000/year

•• Sales of 40,000 CER approximately US$16/CERSales of 40,000 CER approximately US$16/CER = RM1,920,000/year= RM1,920,000/year

•• Total RevenueTotal Revenue = = RM18,720,000/yearRM18,720,000/year

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RE CORE CO--GENERATION SUPPLYING STEAM & POWER FOR GENERATION SUPPLYING STEAM & POWER FOR VALUEVALUE --ADDED DOWNSTREAM MANUFACTURINGADDED DOWNSTREAM MANUFACTURING

POMEPOMESHELL EFB FIBRE MESOCARP FIBRESHELL EFB FIBRE MESOCARP FIBRE

REFINERY REFINERY PLANTPLANT

OLEOCHEMICAL OLEOCHEMICAL PLANTPLANT

TNB GRIDTNB GRID PHYTONUTRIENTS PHYTONUTRIENTS & NUTRACEUTICAL & NUTRACEUTICAL

INDUSTRIESINDUSTRIES

BIOGAS DIGESTER BIOGAS DIGESTER TANKTANK

PALM OIL PALM OIL MILLMILL

KERNEL KERNEL CRUSHING PLANTCRUSHING PLANT

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BIOGAS & BIOMASS BOILER



TNB GRIDTNB GRID PHYTONUTRIENTS PHYTONUTRIENTS & NUTRACEUTICAL & NUTRACEUTICAL



40




CANDLE CANDLE MAKINGMAKING

BAKERYBAKERYTNB GRIDTNB GRID PHYTONUTRIENTS PHYTONUTRIENTS & NUTRACEUTICAL & NUTRACEUTICAL



TEXTILE TEXTILE INDUSTRYINDUSTRY

SOAP MAKINGSOAP MAKING

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Advantages of the RE Advantages of the RE Integrated Palm Oil Industries ComplexIntegrated Palm Oil Industries Complex

•• Minimizing Pollution Problem, Localize ActivitiesMinimizing Pollution Problem, Localize Activities•• Saving of electricity energySaving of electricity energy•• Effective Usage of steam energyEffective Usage of steam energy•• Saving of transportation costSaving of transportation cost•• MaximizeMaximize use of manpower (centralization)use of manpower (centralization)•• Reduce of commuting Reduce of commuting feedstocksfeedstocks•• DeDe--carbonizing the electricity & gas gridcarbonizing the electricity & gas grid•• Reduction of Carbon FootprintsReduction of Carbon Footprints•• Sales of CER from biogas, biomass power plants, Sales of CER from biogas, biomass power plants,

refinery & refinery & oleochemicaloleochemical plant etc.plant etc.•• Enable to produce Carbon Neutral Palm ProductsEnable to produce Carbon Neutral Palm Products

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National Grid (Electricity Distribution)

GREEN & DECARBONING ELECTRICITY TO THE GRID

Carbon-Neutral Pure Palm ® Baby Products

Reduce Carbon FootprintsWith

Carbon Neutral Pure Palm®

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“Kind To Skin, Kind To Environment”

PALM WASTE OPPORTUNITIES

Every 1 mton of CPO produces approximately 11.00 mtons of non-oil biomass & 5 mton non-oil liquid waste (effluent).

Biomass Opportunities exist for all parts of the Industry’s products, which are:• CPO (20% of FFB) = 1.00 mton• Palm Kernel (7% of FFB) = 0.35 mton• Palm Shell (8% of FFB) = 0.40 mton• Mesocarp Fibre (15% of FFB) = 0.75 mton• Empty Fruit Bunches (25% of FFB) = 1.25 mton• Residue & Moisture (25% of FFB) = 1.25 mton• Palm Wood (Trunks) dried weight = 1.17 mton per mton of cpo• Leaves, Fronds & Roots = 6.48 mton per mton of cpo

PALM TRUNK FRONDS EMPTY FRUIT BUNCHES

VARIETIES OF PALM PRODUCTS

• Palm waste can be turned into green wealth utilizing renewable energy to produce carbon-neutral palm products for the benefit of the people & our nation.

There is a growing global market for green products & other value-added palmbased products produced from the palm biomass. The palm oil industry could create an industry from palm waste to generate jobs & wealth for the community surrounding the palm oil mill.

• Small & medium industries such as food & bakery, soap-making, candle-making, automative part composite forming, activated carbon, medium density fibreboardor any industries that require steam & electricity for processing could be set up surrounding the palm oil mill that act as a Green Independent Power Producer.

Palm Fiber Plastic Composite Activated Carbon Medium Density Fiberboard & Particleboard

PALM WOOD PRODUCTS• flooring• furniture• building

construction• bowls• accessories• paper• packaging

Processed palm wood is resistant to termites, mould & wood rot, making palm wood suitable for both interiors & exteriors in both wet & dry climates. Possible to replace almost if not all metal & glass furniture for lower carbon footprint.

kg CO2/kg material produced• Steel 23.9• Aluminium 12.0• Glass, not recycled 8.4• Glass, recycled 1.4• Palm wood - 1.5

PALM FLOORING PALM PLYWOOD P ALM ACCESSORIES

CORPORATE & SOCIAL RESPONSIBILITYEMPLOYMENT - The palm oil Industry is a big employer in Malaysi a. 600,000 people are employed in the growing, harvest ing & processing of palm products. Add to that are the support service s to the industry with an employment figure of about 1 million people.CAREERS - Palm oil milling companies generates long term sus tainable jobs, from low technology base to knowledge-based jobs for the very large bank of knowledge-based graduates from the ma ny institutions of higher learning in Malaysia. This industry provides & offers careers. Not just jobs but careers to grow professionally & achi eve job satisfaction.POVERTY ERADICATION - Without job employment in the palm oil industry, more than 1.6 million Malaysians would ha ve considerable difficulty in feeding themselves & their families, not to mention supporting an education.SOCIAL ENTREPRENEURSHIP (Two Prong Benefits) – Firstly, the palm oil industry gives small land owners around the cou ntry, greater opportunities to make a better living off their lan d, thereby eradicating poverty through Wealth Creation - providing the poor a path out of poverty. This result in a sense of self-worth whic h can never be gained from a cash handout. Secondly, social entrepreneur can also leverage on the green energy supply from the Palm Oil Mills to set up cottage in dustries to provide jobs transferring wealth to the poor to further social & environmental goals.

“An Inconvenient Truth ”

THE TROPICAL TRUTH

TheTropical CarbonSink

TheTropical CarbonSink Belt

CALCULATION OF CAPTURED CO2 PER MTON OF CPO

• Non-oil palm biomass = 52.30% carbon on a dry weigh t basis

• 1 mton of CPO = 11 mton of dry palm biomass

• 11 mton of dry palm biomass = 11 x 52.30% = 5.75 ton s captured carbon

• Molecular weight of Carbon = 12• Total Molecular weight of CO 2 = 12 + (2 x 16) = 44• 1 mton of Carbon = 44 /12

= 3.67 times of CO 2 captured from the atmosphere

• 5.75 tons captured Carbon in palm biomass = 5.75 x 3.67 = 21.10 tons captured CO 2

• Therefore, 17 million mton of CPO absorb = 358.87 million tons of captured CO 2

• If World CPO production up 100 million mton = 2,110 million tons of captured CO 2

• 1 Hectare of Oil Palm Plantation absorb = 92.88 ton s of captured CO 2

Conclusion• BELL Group is excited with the development of the b iogas &

biomass green power plants using green energy techn ology as there is full potential to transform the industry i nto a totallyGreen Agro-based Industry & taking green power gene ration to the next level.

• Anaerobic Digestion is not a subject that pops up o ver dinner parties as it can put people off! The challenge fo r BELL Group is to make anaerobic digestion, “sexy & beautiful” - & position Biogas Power Plants to be the most exciting RE pow er cycle system in the Palm Oil Industry.

• We now have the know-how & the technology to beauti fy, clean up & modernise the Palm Oil Industry & change the world’s perspective on methane emissions, dirty Pa lm Oil Mills & climate change.

• Our government should develop & create Palm Oil Ind ustry as a Green Tourism Destination. An eye opening experie nce to visitors as they can observe how all the by-product of the palm oil process normally considered as waste is transfo rmed into green energy contributing to a green economy.

Conclusion• Ladies & gentlemen, I stand proud to be here today to share

with you the burgeoning potential of this industry. I strongly believe we are on the right tract to move in tandem with the economy & with our response to climate change & ot her environmental concerns. We have been made aware of climate change. Unlike others in other industry, we are n ot waiting for help but we have invested heavily on R&D to come up with a solution to the problem.

• We CAN ACHIEVE ZERO WASTE, LOW CARBON FOOTPRINTS & PRODUCE RENEWABLE ENERGY

• With these claims, we know that this industry is su stainable & is for everyone. In whatever level of the business you decide to come in, be it in planting the crops or downstream processing, this is an industry that will allow you to grow & e xpand your business & economic base. The concept of waste to wealth is not a myth in the Palm Oil Industry. I should know because I started with only 1 palm oil mill. Today, I am in so many different aspects of the industry. The potentials ar e many & the opportunities are aplenty.

Thank YouThank [email protected]

* The background image is our POM Effluent Pond Scenery with all the Beautiful White Migrant Birds.

Documents

Converting Palm Waste to WealthConverting Palm Waste to …poic.com.my/files/palmex/P1.pdf · Special Features of Digester Tank BELL Eco Power Sdn. Bhd. Digester Tanks Comparison