PIGGAREP Abemama Island Biofuel Power Generation ......Miriam TIKANA PIGGAREP coordinator for Kiribati MPWU - EPU Mwaati TOROMON MPWU – EPU Beria OROMITA MPWU - EPU Abemama Biofuel

PIGGAREP

Abemama Island Biofuel Power Generation Preparatory Work

SIDS DOCK Support Program

Montpellier September 2014 Draft 2

Deliverable 1, 2, 3, 4

Abemama Biofuel Power Generation preparatory work

2

Acknowledgement

The expert wishes to acknowledge the support and assistance of the following people without who this

preparatory work would not have been carried out in such efficient conditions: Mrs. Mwaati Toromon,

Mr. Beria Oromiti and Mrs. Miriam Tikana.

Gilles Vaitilingom

August 2014

Revised September 2014


3

Acknowledgement 2

People interviewed 5

Acronyms and units 6

I. Background 7

II. Preliminary findings of the on-site activities 8

Objective 8

Methodology 9

Preliminary findings 9

Conclusion 11

III. Preparation of installation Design of Biofuel-based 12

Power Generation Systems

Biofuel Power Generation Equipment sizing Updating

Overall description and equipment sizing 12

Abemama Island Council 15

Kauma High School 15

Chevalier College 15

Risks 16

IV. Terms of Reference for the supply of the Biofuel Mill 17

and the biofuel power generation systems.

Biofuel Mill building 17

Power house Island Council building 20

CNO coconut oil biofuel production 20

Quality control of CNO Biofuel 22

Biofuel power generation 23

Take-off lists 26

V. Terms of Reference for the installation of the Biofuel 30

Mill and the biofuel power generation systems.

Transport 30


4

Biofuel Mill building installation, testing and commissioning 30

CNO coconut oil biofuel production installation, testing 33

and commissioning

Biofuel Power Generation installation, testing and commissioning 33

Monitoring 34

Capacity building 35

Performance evaluation 37

Floor Plan 39

Annex 1: example of logbook

Annex 2: Quality standard of CNO


5

People interviewed

Paul TEKANENE CEO KCMCL

Momoe KAAN Acting Business Promotion Centre

Maraki BOKAI CEO KCCS

Ritaia ABIATA Deputy Principal Kauma Adventist High School Abemama

Teena KUM KEE Principal Chevalier College Abemama

Motirake ATANATI Mayor of Abemama

Teebeta BAARINGA Acting Clerk Island Council Abemama

Maawata UTARA Treasurer Ministry of Internal Affairs Abemama

Karotu TOAURU Assistant treasurer Ministry of Internal Affairs Abemama

Miriam TIKANA PIGGAREP coordinator for Kiribati MPWU - EPU

Mwaati TOROMON MPWU – EPU

Beria OROMITA MPWU - EPU


6

Acronyms and units

SPREP Secretariat of the Pacific Regional Environment Programme

UNDP United Nations Development Programme

GEF Global Environment Facility

PIGGAREP Pacific Islands Greenhouse Gas Abatement through Renewable Energy Project

MPWU Ministry of Public Works and Utilities

EPU Energy Planning Unit

KCCS Kiribati Copra Cooperative Society

KCMCL Kiribati Copra Mill Company Ltd

CNO Coconut Oil (extracted from dried copra)

DFO Diesel Fuel Oil

PV PhotoVoltaic

IDI InDirect Injection diesel engine

DI Direct Injection diesel engine

ppm parts per million

Energy units

KVA Kilo Volt Amperes

kW Kilowatt

kWh Kilowatt hour

kWp Kilowatt peak max. power from PV panels, at standard conditions

AC

Conversion factors

Energy content coconut oil/Diesel (in volume) 1.08

Density of copra (kg/l) 0.915

Extraction rate of oil from dried copra (%) 55 in small capacity mill


7

I. Background

The copra industry in Kiribati, where the dried meat of the coconut is used to extract coconut oil

(CNO), contributes about a quarter of the country’s GDP. Considering the increasing importance of

CNO as a biofuel when comparing the CNO prices and diesel fuel oil (DFO) prices in recent years, the

Government of Kiribati plans to use CNO produced from copra to replace up to 90% of the DFO used

in power generation in the country.

Biofuel production and use in Kiribati are intended to realize the following:

• Reduction of shipping cost of copra from the outer islands to Tarawa;

• Improvement of national energy security and creation of a local biofuel industry;

• Reduced risk of environmental damage from diesel fuel spillage

• Achievement of economy of scale through milling the entire copra production.

A feasibility study funded by the UNDP-GEF Pacific Islands Greenhouse Gas Abatement through

Renewable Energy Project (PIGGAREP) on the viability of producing and utilizing CNO for power

generation in Kiritimati gave favorable results. Based on the results of the feasibility study in Kirimati,

the island of Abemama will develop a scheme to generate biofuel from its copra resources and utilize

it for electricity generation in the island. There is currently no CNO production in Abemama Island.

This project will involve the installation of a biofuel mill that will produce coconut oil (CNO). This CNO

will be blended with DFO and the biofuel blend will be used as fuel to replace the DFO used in 3

existing diesel power generating facilities in Abemama Island. These are in the Island Council and two

secondary schools; Kauma and Chevalier. The goal is to displace a bulk of the annual diesel fuel oil

consumption for power generation in the island with CNO. The use of CNO will be done gradually by

blending it with DFO starting at 30% by volume (30-70 CNO-DFO blend). Then this will be gradually

increased up to the target 90-10 CNO-DFO blend.

Abemama Island.


8

Source: Republic of Kiribati Island Report Series; 2012 Office of Te Beretitenti & T’Makei Services.

II. Preliminary findings of the on-site activities

Objective

The on-site mission was conducted to assess the information and preliminary design given by the

recent survey done by the Energy Planning Unit and to gather all data necessary to prepare the

installation design of a Biofuel-based power generation in Abemama.


9

Methodology

Meetings were held in Tarawa with the Energy Planning Unit (MPWU), the Kiribati Copra Mill

Company (KCMCL), the Ministry of Commerce and the Kiribati Copra Cooperative (KCCS). After that,

a 3 days mission was undertaken to Abemama accompanied by a member of the EPU staff. In

Abemama, activities to fulfil the expected results on the 3 sites have been conducted in collaboration

with the relevant stakeholders, government entities and local communities.

Preliminary findings

An update of the data and assumptions given by a recent survey of the EPU was conducted in order

to confirm the sizing of the Biofuel power generation equipment.

On the arrival of this mission, none of the three sites was using DFO to generate power. This situation

seemed to last for months.

• Kauma High School:

The two Diesel generators are out of order, one is definitely worn out and the second one,

oversized for a possible CNO fuel adaptation, has a broken alternator. Electricity is currently

provided by a small gasoline genset (2600 W) during some working hours. But the school is

about to start up a PV field (43 kWp) and a bank of batteries able to deliver power during 6 to

10 hours per day. The underground distribution lines are in good conditions. Kauma High

School is still interested to run on CNO biofuel in substitution of the gasoline generator to

power the campus and office during working hours.

Current Kauma power system……………… Kauma 80 KVA genset (oversized) out of order.

Kauma power system in a very near future.


10

• Chevalier College:

The college is running a pair of small gasoline gensets (6600 W) for the office and classroom

needs of power and for night lighting. A brand new 10 KVA diesel generator has arrived last

June donated by the Chevalier College of Australia. But the underground distribution lines

are worn out then no power can be distributed (they were scheduled for replacement in

2007). The college will be happy to run their 10 KVA genset on CNO biofuel as soon as they

ended up the grid renovation.

Current Chevalier college power system

• Island Council:

As reported by the recent EPU survey, analysis of existing distribution lines for the Island

Council system indicates that they are worn out. A small gasoline portable generator set

(2600 W) is now used to supply electricity to the Island Council-operated hotel; and the

council member houses now use solar home systems (for lighting, video and radio only). The

Council power house has an old 25 KVA diesel generator which is used only for powering a

welding machine some hours per week. A 10 KVA genset will be sufficient to power the

Island Council compound. It must be oversized if it also powers the oil mill.

The Island Council power house.


11

Conclusion

Based on these preliminary findings, it appears that solar systems are successful and have taken a

part in energy procurement thus replacing significant quantities of diesel fuel, except for Chevalier

College. Two of the 3 sites are not in position to use CNO biofuel because of the failure of their

distribution lines. This needs immediate improvements. Chevalier has a plan of replacing its grid soon

for a price of 20,000 AUD (equipment and labor included), of which they have 18,000 AUD available.

The island Council has estimated the cost of installing a grid at 7,000 AUD (for the equipment only,

the work will be done by the Island Council themselves). It can be recommended that there should

be further clarity and commitment from Abemama’s side on actually installing these grids before the

Project invests in Biofuel generation systems.

The option to improve or upgrade the existing gensets to make them able to run on CNO is not

viable: Kauma’s are worn out, too old and oversized (80 KVA); the Island Council Diesel generator is

also old and oversized; Chevalier’ brand new genset is not able to run on blends of CNO-DFO, this is

due to its technical design.

The Biofuel Power Generation Project in Abemama must be reviewed in the light of these new

elements. Therefore, based on the uncertainties regarding grid and the new items (generators,

building for copra mill and power house) that were not budgeted in the original project

document, it might have to consider only installing 2 rather than 3 sites (due to budget

constraints). But, as developed in the next chapter, the saving on the budget by canceling

Kauma or Chevalier site, are estimated to be around 10,000 to 15,000 USD. But, should it be

the case, it is preferable to keep Chevalier because the College will consume two times more

CNO than Kauma High School.

Abemama future Biofuel Oil Mill and Power House.


12

III. Preparation of installation Design of Biofuel-based Power Generation

Systems

Biofuel Power Generation Equipment sizing updating

This project involves the installation of a Biofuel Mill that will produce coconut oil (CNO). This CNO

will be blended with DFO and the biofuel blend will be used as fuel to replace the DFO in 3 power

generating facilities in Abemama Island. These are the Island Council and two secondary schools;

Kauma and Chevalier.

Assessment of CNO Biofuel needs

Kauma High School:

Most of the energy demand will be fulfilled by the new PV field. Their need in power from DFO, or

CNO, will not excess 8 kW (10 KVA). The projected load profile from Diesel generation is given by the

next figure.

• DFO Running hours per day: 5 • Average load kW: 5 • Energy demand per day kWh 25 (from DFO) • Peak load kW: 8 • % time at peak load: 25 • DFO average consumption per day: 8 litres

Chevalier College:


13

The projected load profile is given in the figure below.

• DFO Running hours per day: 17 • Average load kW: 3.3 • Energy demand per day kWh 56 • Peak load kW: 8 • % time at peak load: 6 • DFO average consumption per day: 18 litres

Island Council compound:

The projected load profile, including the oil mill, is given in the figure below.

For the grid and the oil mill:

0

2

4

6

8

10

12

14

1 3 5 7 9 11 13 15 17 19 21 23

kW

hour

Island Council

Oil mill

grid

total


14

• DFO Running hours per day: 13 • Average load kW: 5.6 • Energy demand per day kWh 73 • Peak load kW: 13 • % time at peak load: 7 • DFO average consumption per day: 24 litres

Altogether, the three sites will consumed an average of 50 litres of DFO per day for power

generation. As a first approach, this gives an equivalence of 55 litres of CNO while using the energy

content conversion factor DFO/CNO. This data will be used in the following assessment even for the

30-70 CNO-DFO blend.

The two table below give the material balances of the starting at 30% by volume of CNO (30-70 CNO-

DFO blend), and of the objective to reach 90% by volume of CNO (90-10 CNO-DFO blend). The

calculation is made on 365 days a year. The production will be based on 240 working days per year.

30-70 CNO-DFO blend Q/day (365) Q/month Q/year

Copra (kg) 30 900 10,800

CNO (liter) 16.5 495 5940

DFO (liter) 38.5 1,155 13,860

30-70 (liter) 55 1,650 19,800

Copra cake (kg) 12 360 4,320


Copra (kg) 90 2,700 32,400

CNO (liter) 49.5 1,485 17,820

DFO (liter) 5.5 165 1,980

90-10 (liter) 55 1,650 19,800

Coprah cake (kg) 36 1,080 12,960

The mill will have a capacity of 80 liter of CNO per day on the basis of 240 production days per year.

With a conventional expeller that uses dried copra as a feedstock, this means an average of 140 kg of

dried copra processed per day.

The assessment of the volume of CNO for power generation in the 3 project sites gives an annual

maximum use of around 30-35 metric tons of copra. This represents less than 4% of Abemama

production, which therefore will remain a copra producer island.


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Overall description and sizing of the equipment

Island Council installation:

o The Biofuel Mill will require a new building in the area of the Council; it is separated in

three sections: copra storage, the mill workshop and the CNO final storage and blending

facilities.

o A power house will host the CNO biofuel genset powering the Biofuel mill. This power

house can be built against the Mill or as a separated construction.

o The capacity of the oil will be in the range of 40 to 100 kg of copra per hour.

o The power generator of the Mill will also serve to supply electricity to the Island Council

Compound grid.

o The electricity board with the mains switches supplying the grid must be replaced.

o The underground grid must be provided.

o A 15 to 20 KVA genset able to run on pure CNO (100%) will be required for this site. A

recent quotation from Australia, has given a price of 9700 USD ex GST for a 20 KVA.

Details are given in the TORs and ROPs.

Kauma High School:

o The existing power house is relatively clean and safe.

o The electricity board with mains switches supplying the grid is being renovated.

o A 10 to 15 KVA genset able to run on pure CNO (100%) is required for this site. A

recent quotation from Australia, has given a price of 8500 USD ex GST for a 12 KVA.


Chevalier College:

o The existing concrete built power house is relatively clean and safe.

o The electricity board with the mains switches supplying the grid must be replaced.

o The underground grid is worn out and must be replaced.

o A 10 to 15 KVA genset able to run on pure CNO (100%) is required for this site, taking

into account that their new generator is not adapted to use CNO as fuel. A recent

quotation from Australia, has given a price of 8500 USD ex GST for a 12 KVA.



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Risks

1. Weak CNO production and poor quality oil due to bad performance of the oil expeller and

filtration/conditioning units, resulting in financial loss and loss of motivation.

* This can be detected early by the CNO quality control: water content and Acid value at EPU

facilities, and content in sediment with support of KOIL (?).

* This can be avoided if the tender specifications are respected and if performance evaluations

occur during the commissioning.

2. Bad running and/or bad performances of the gensets: inability to provide the power demand,

bad efficiency - overconsumption.

* This can be detected since the performance evaluation thanks to the “90-10 CNO-DFO” blend

test; even if the current operation is defined to start with 30-70 CNO-DFO blend.

* This can be avoided if the tender specifications are respected and if the performance

evaluations occur during the commissioning.

3. Procurement and installation of a PV field at Chevalier College, similar to the existing Kauma PV

system; in addition with a few power demands from the Island Council compound, due to

absence of grid since years (many SHS installed). These will seriously reduce the volume of CNO

needed as biofuel, may be up to the point of provoking a disinterest in the oil mill.

* One solution might be the reorientation of the project, which would then become a project for

Energy Self-sufficient Decentralized Production of CNO in Outer Island. This could happen only if

the project receives political support, giving KCMCL obligation to buy all the CNO and cake

produced by the Abemama Oil Mill. Or, if PUB buys the CNO for blending in the power fuel in

Tarawa (very low rates therefore no technical risks). Or, finally, if KSSL buys the CNO for use as

fuel in its ships in dual-fuel mode.

4. Poor management of the Oil Mill, leading to poor CNO production provoking a disinterest in

the oil mill activity.

* The agreement with the Island Council must involve all the stakeholders and define

responsibilities, property of building and equipment, and a detailed monitoring.


17

IV. Terms of Reference for the supply of the Biofuel Mill and the biofuel

power generation systems.

This project involves the installation of a Biofuel Mill that will produce coconut oil (CNO). This CNO

will be blended with DFO and the biofuel blend will be used as fuel to replace the DFO in 3 power

generating facilities in Abemama Island. These are the Island Council and two secondary schools;

Kauma and Chevalier.

The two table below give the material balances of the starting at 30% by volume of CNO (30-70 CNO-

DFO blend), and of the objective to reach 90% by volume of CNO (90-10 CNO-DFO blend). The

calculation is made on 365 days a year. The production will be based on 240 working days per year.


Copra (kg) 30 900 10,800

CNO (liter) 16.5 495 5940

DFO (liter) 38.5 1,155 13,860

30-70 (liter) 55 1,650 19,800

Copra cake (kg) 12 360 4,320


Copra (kg) 90 2,700 32,400

CNO (liter) 49.5 1,485 17,820

DFO (liter) 5.5 165 1,980

90-10 (liter) 55 1,650 19,800

Coprah cake (kg) 36 1,080 12,960

Technical specification list and Take-off lists.

The dimensions, volumes and capacity given here are given as minimum.

Biofuel Mill building

- The bidders must quote and provide all material and structure needed for the

construction of the building. See floor plan and elevation plan in the TORs for the

installation.


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- The water supply will come from the existing water distribution network.

Offers must include the provision of:

- A main water shutoff valve 1”

- 1 sanitary manifold 1” – 3 x 3/4”

- 3 wall mounted taps ¾ ‘’(one in each section)

- 100 meters of PE water pipe ¾”

- All fittings and pipe hangers for pipe ¾”

- 3 x 15 meters of water flexible hose ¾” (to be mounted on taps)

- Electrical

Bidders must follow the Australian/New Zealand Standards. Current is rated at 10 amps for single

phase wiring and 20 amps for three phase wiring.


- Cable, cable tray, hangers,…

- for connection from the power house to the electrical cabinet in the Final storage

- and for the electrical network of the whole building

- The electrical cabinet of the building

- Sewage and waste water treatment

During the CNO production and conditioning no chemicals are used, waste are the results of floor,

machine and vessels cleaning with soda based detergents.


1 Collecting tank or septic system in order to treat these waste water effluents. Volume is

estimated at 100 liters per week.

- Copra storage:


1 door opening: Lxh = 2.00 x 2.10 m. Can be double doors.

Venting of heat from ceiling in upper part of the walls (metal grates or louvre).

2 windows: Hxl = 1.30 x 1,20 m

1 simple door Lxl = 0.80 x 2.10 m.

Electrical section:


19

2 ceiling lamps (energy efficient lighting, e.g., CFLs 23-30W or LED lamps)

1 switch

1 double 10 amp single phase Australian socket outlet

- Oil mill section


Venting of heat from ceiling in upper part of the walls (metal grates).

4 windows: Hxl = 1.30 x 1,20 m

1 large door (opening: Lxl = 2.00 x 2.10 m.)

Electrical section:


2 switches

4 Australian 20 amps 5-pin 3-phase socket outlet, with both earth and neutral connections,

IP56

4 20 A 400 V 3P+N+E plug, Australian


2 ceiling fans 50’’ ; 70W

Workshop section:

- 1 sorting table: Lxlxh = 3.00 x 1.00 x 0.90; wood or metal

- 1 support frame valet for cake bagging

- 10 buckets, volume 30 liters; plastic

- 1 scale ; capacity 150 kg

- 100 bags ; capacity 30 kg of cake, polypropylene

- 6 brooms

- 2 funnels (diam. 30 cm)

- 1 dustbin, 100 liters

- Final storage section



Electrical section:


1 switch

1 Australian 20 amp 5-pin 3-phase socket outlet, with both earth and neutral connections,

IP56




20

1 ceiling fan 50’’ ; 70W

The electrical cabinet of the building including electricity meter

1 extension cord 20 meters

- Miscellaneous spares



2 switches



IP56


Power house Island Council building



Electrical section:


1 switch

1 main circuit breakers board for connection to

The Biofuel Mill building

The Island Council underground grid

1 main electricity meter

CNO coconut oil biofuel production

The nominal required quantity of CNO per working day is estimated at 80 liter.

With a conventional expeller that uses dried copra as a feedstock, this means an average of 140 kg of

dried copra processed per day. It is expected that this quantity can be milled in a shift of maximum 4

hours.

The use of CNO will be done gradually by blending it with DFO starting at 30% by volume (30-70 CNO-

DFO blend). Then this will be gradually increased up to the target 90-10 CNO-DFO blend.

A classical mini oil mill plant is described hereafter, the technology is indicated as an example, and

offers should propose equipment able to fulfil the following sizing recommendations.


21


1. Copra shredder:

• Hammer mill, frame-mounted, screens size 1 to 2 cm

• Capacity: 100 kg per hour.

• Electric motor 240/400 V, three phase, 50 Hz, IP55.

• Breaker 4 poles with security and emergency stop (kill switch).

• Cable 5 wires, 5 meters

• Spares parts for 1,000 hours (set of hammers, screen)

• List of maintenance spares for 1000 hours

• Operating and maintenance manual

• Spare parts catalog for hammer mill and motor

• Length : m , width : m, height : m , weight : kg

2. Oil expeller :

• Able to process crushed copra (outlet size: 1 - 2 cm.)

• Frame-mounted

• References with copra and extraction rate

• Capacity: (copra/h.) 35 to 80 kg/hr.

• Electric motor 240/400 V, three phase, 50 Hz, IP55.


• Preheating of the oil outlet tube is possible (in case of hole cylinder tube).

• Preheating of crushed copra by the means of an external boiler is not eligible.

• Breaker 4 poles with security and emergency stop (kill switch).

• Electrical hour meter.

• Spares parts for 1,000 hours

• Set for one complete overhaul (barrels/rings/hole cylinder, 1 screw)

• List of maintenance spares for 1000 hours

• Operating and maintenance manual

• Spare parts catalog for the expeller and motor

• Length : m , width : m, height : m , weight : kg

3. Filtration and conditioning unit:

• Crude oil sedimentation tank capacity: 250 liters/ 3 baffles.

• First filtration grade: around 100 µm. Washable.

• First oil pump manually operated (could be electrical)

• First storage tank volume: 300 liters. Metal or PEHD (with drain plug and 200 mm

min. diam. opening on top)

• Second filtration grade: 10 µm

• Oil pump electric motor 240/400V, three phase,50 Hz, IP55.

• Minimum oil pump flow rate: 500 l/hr.

• Final storage tank volume: 1000 liters. Metal or PEHD (with drain plug; 300 mm

minimum diam. opening on top; 2’’ fittings on top, mechanical level indicator)

• All pipes and hose necessary for operation.


• Spares for 15000 liters CNO


22

• CNO-DFO Biofuel tank volume: 500 liters. Metal or PEHD (with drain plug; 300 mm

minimum diam. opening on top; 2’’ fittings on top, mechanical level indicator)

• DFO tank: drum 200 liters.

• 1 Manual refueling drum pump,

• 2 x Filling stations with nozzle and meter; each composed of:

(1) Fuel transfer pump, 240V single phase( or three phase)

(1) 3/4in. x 50cm–80 cm steel telescoping suction pipe

(1) 3/4in. x 4 meters hose with static ground wire

(1) 3/4in. manual nozzle

(1) 5 m., AC cable

(1) Volumetric mechanical meter in liter

• List of maintenance spares for 15000 liters CNO

• Operating and maintenance manual of each equipment

• Spare parts catalog for the pump and motor

• Length : m , width : m, height : m , weight : kg of tanks and filtration

components

Quality control of CNO Biofuel

The control of CNO samples will involve two parameters.

- Water content (maximum: 1000 ppm)

- Content of FFA (Acid Value, maximum: 10 mg KOH/g)


1 Karl Fisher lab apparatus (ref. ISO 6296)

1 titration tool kit.

Example of Karl Fisher lab apparatus and titration tool kit for Acid value determination.


23

Biofuel power generation

The Three gensets will be installed in the existing power house for Kauma High School and Chevalier

College, and in the new power house at the Island Council Biofuel Mill.

Description

The gensets outlines are enclosed or open set type.

Offers must include the provision of three gensets:

• Kauma high School CNO generator (10 – 15 KVA)

o Must be motorized with an IDI engine equipped with inline injection pump or rotary

Bosch (or licensed) type VE only. (No DI engines are accepted. Except if references

and full warranty are specifically given for the use of 100% CNO).

o Must be able to run on 100% CNO

o With one of each fuel, DFO and CNO, and any blends of the two, the genset must

provide the power indicated (in the range of 10 to 15 KVA) in prime rating

o Filtration system must be adapted to a cinematic viscosity of 15 cSt (dynamic: 20

mPa.s), this can be achieved with a fuel heater or by oversizing the filtration surface.

o Alternator : 3 phase, 4 wires, 50 Hz, voltage 400/230, power factor 0.8, IP23

o Control panel must be included

o Exhaust must be included


24

o Batteries must be included.

o Spares for 2000 hours must be included

• Chevalier College CNO generator (10 – 15 KVA)














• Island Council and Biofuel Mill CNO generator (15 -20 KVA)














FOR EACH GENERATOR, offers must describe the following item:

GENSET type :

o Prime power 24/24 : KVA.

o Standby power: KVA.

o Voltage: V

o Frequency: 50 Hz

o Power factor: 0.8

To be considered : Basic conditions:


25

o Temperature: in the range of 26° to 32 °C

o Altitude: elevation < 5 meters

o Humidity: average 87%

DIESEL ENGINE:

o Manufacturer:

o Type:

o Power: kW

o Speed: RPM

o Cooling:

o Cycle: 4 strokes

o Inlet:

o Injection: pump

o Cylinders:

o Bore / Stroke:

o Displacement:

o Compression ratio:

o Regulation:

Equipped with:

o First fuel filter: if applicable

o Last fuel filter: if applicable

o Special coconut oil delivery system: if applicable

o Lubricant filter:

o Air filter:

o Electrical starter: VDC

o Alternator: VDC Amp

o Security:

ALTERNATOR

o Manufacturer:

o Type:

o Version:

o Speed: RPM

o Power: KVA

o Frequency: 50 Hz

o Voltage: 400 Volts

o Power factor: 0,8

o Insulation:

o Protection: IP23

o Regulation: +/- %.

SUPPLY:

o Batteries:

o Exhaust gas tube:

o Breaker 4 poles with security.


26

o Control and security panel:

o Description of the control panel:

Ammeter:

Voltmeter:

Frequency meter:

Hour meter:

Energy meter:

Starting key:

Electronic security module:

Warning lights and/or automatic stop for:

Battery charge default:

Overheating of cooling air:

Low oil pressure:

Overheating of cooling air:

Low oil pressure:

Overspeed:

o List of maintenance spares for 2000 hours:

o Operating and maintenance manual:

o Listing of spare parts for the engine and the alternator:

o Length : m , width : m, height : m , weight : kg.

Take-off lists.

Biofuel Mill Building

Power House


Quality Control CNO

Island Council underground Grid

Biofuel Power Generation


27

BioFuel Mill Building

Equipement Unit Quantity

main water shutoff valve 1’’ unit 1

Sanitary manifold size 1’’ outlet 3-3/4’’ unit 1

wall mounted tap 3/4 '' unit 3

PE water pipe ¾’’ meter 100

fittings, pipes, hangers,…for pipes ¾’’ set 1

water hose flexible ¾’’ meter 45

cable, cable trays, hangers according floor plan dimension set 1

electrical cabinet (including electricity meter) unit 1

collecting tank (sewage) 1m3 unit 1

windows 1.30 x 1.20 m. (width x height) unit 7

door 0.80 x 2.10 m. (width x height) unit 1

ceiling lamp (energy efficient lighting, e.g., CFLs 23-30W or LED lamps) unit 8

switch unit 4

double 10 amp single phase Australian socket outlet unit 4

opening door 2.00 x 2.10 m. (width x height) Unit 3

Australian 20 amps 5-pin 3-phase socket outlet, with both earth and

neutral Unit 5

connections, IP56

20 A 400 V 3P+N+E plug, Australian Unit 5

ceiling fan 50’’ ; 70W Unit 3

sorting table 3.00 x 1.00 x 0.90 m. (Length x width x heigh) wood or

metal Unit 1

support frame valet for bagging (copra cake) Unit 1

bucket 30 liters platic Unit 10

scale 0-150 kg Unit 1

bag , for 30 kg cake, polypropylene Unit 100

broom Unit 6

funnel diam. 30 cm. Unit 2

dustbin 100 liters Unit 1

extension cord 1P+N+E meter 20

spares


Australian 20 amps 5-pin 3-phase socket outlet, with both earth and

neutral Unit 2

connections, IP56

20 A 400 V 3P+N+E plug, Australian Unit 2


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Power House


door 2.00 x 2.10 m. (width x height) Unit 1


switch Unit 1

Main circuit breaker package 1

CNO production


copra shredder frame-mounted 100 kg/h , 240/400 V, three phase, 50

Hz, IP55 package 1

(see details in TORs)

oil expeller, capacity 35-80 kg crushed copra/hr. frame-mounted package 1

240/400 V , three phase, 50 Hz, IP55 (see details in TORs)

filtration and conditioning

crude CNO sedimentation tank, 3 baffles, 250 liters Unit 1

First filter (grade around 100 microns) package 1

manually operated pump Unit 1

storage tank 300 liters (see details in TORs) Unit 1

second filter (grade around 10 microns) package 1

CNO oil pump 240/400 V three phases, 50 Hz, IP55 Unit 1

final storage tank 1000 liters (see details in TORs) Unit 1

all pipes and cables (see details in TORs) set 1

CNO-DFO Biofuel tank, 500 liters Unit 1

manual refueling drum pump Unit 1

DFO tank, drum Unit 1

Filling station (see details in TORs) package 2

Quality control CNO


"Karl Fisher" type apparatus package 1

Acid Value titration tool kit (completed) package 1


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genset, enclosed or open set type, from 10 to 15 KVA (see details in TORs) package 2

genset, enclosed or open set type, from 15 to 20 KVA (see details in TORs) package 1


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V. Terms of Reference for the installation of the Biofuel Mill and the biofuel

power generation systems.

Transport

The bidders must organize themselves and estimate the costs of transport of all the items,

equipment and material. Freight can be shipped in a full container from oversea to Betio. FCL is full

container load, and is available in 20ft or 40ft containers. LCL is with some boxes or pallets, when you

do not want to ship a full container.

From Betio, transport can be done by sea; private companies are operating landing crafts between

Tarawa and Abemama. Shipping companies and agents can be contacted in Betio.

Biofuel Mill building installation, testing and commissioning

The building will be in corrugated metal sheet walls (or blockwall), separated in three sections: copra

storage able to host one month of feedstock, the mill workshop and the CNO final storage, blending

facilities and cake storage. A power house, concrete built, will host the CNO biofuel genset powering

the Biofuel mill.


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Description

• The dimensions given here can be scaled to fit standards material sizes and standard of

construction in progress.

• The floor of the building is made of concrete 15 cm thick.

• The walls are of concrete or metal siding.

• A water circuit, connected to an existing pipe, is distributing water to 3 taps, one in each section.

• Roof: galvanized steel corrugated panels.

• Copra storage: Lxl = 5x7 ; 35 m2.

Door opening: Lxh = 2.50 x 2.10 m. Can be double doors.

There must be ventilation in upper part of the walls (metal grates).

Two windows on each side on the double doors: Hxl = 1.30 x 1.20 m

A simple door (Lxl = 2.10 x 0.80 m.) to have access to the mill workshop from the inside.

Electrical section:


1 switch


• Oil mill workshop: Lxl = 6x7 ; 42 m2

There must be ventilation in upper part of the walls (metal grates) and 2 ceiling fans.

Four windows, two on each side of the external walls: Hxl = 1.30 x 1,20 m

A large door (opening: Lxl = 2.00 x 2.10 m.) to have access to the final storage from the

inside.

Electrical section:


2 switches

4 Australian 20 amps 5-pin 3-phase socket outlet, with both earth and neutral connections,

IP56


2 ceiling fans (50’’; 70W)


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• Final storage: Lxl = 6x4 ; 24 m2


Electrical section:


1 switch


IP56


1 ceiling fan (50’’; 70W)

The electrical cabinet of the building

• Power house: Lxl = 6x3 ; 18 m2

Preferably built of concrete blocks.

There must be ventilation in upper part of the walls (metal grates or expanded metal).


Electrical section:

1 ceiling lamp (energy efficient lighting, e.g., CFLs 23-30W or LED lamps)

1 switch

1 main breaker board

• Sewage and waste water treatment

During the CNO production and conditioning no chemicals are used, waste are the results of floor,

machine and vessels cleaning with soda based detergents.

A collecting tank or septic system will be installed in order to treat these waste water effluents.


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CNO coconut oil biofuel production installation, testing and commissioning

Installation, testing and commissioning may follow the following process sheet. But a degree of

freedom is left to optimize the ergonomics of the facilities.

• Making CNO and cake

1. Bags of copra are stored in the copra storage. Then each bag is sorted on a sorting table.

2. Sorted copra is kept in buckets before being crushed in the copra shredder.

3. Crushed copra is weighted (scale 150 kg).

4. Then crushed copra is introduced in the hopper of the oil expeller.

5. Raw oil flows into the sedimentation tank.

6. Copra cake is kept in a bucket enough time for it to cool down at room temperature.

7. Then cake is put in polypropylene bags hanged by a valet.

8. Each bag of cake is weighted.

9. Full cake bags are then transported and stored in the Final storage section.

• Conditioning the raw coconut oil

1. When full, and after 24 hours of standby, raw oil is manually pumped from the

sedimentation tank and passes through the first filtration to the 300 l. tank.

2. When full, it is pumped through the second filtration to the final tank (1000 l.)

• Making blend CNO-DFO

1. DFO is pumped from drum through the CNO-DFO Biofuel tank (500 l.) with the refueling

drum pump, DFO quantities are noted in a logbook.

2. CNO is pumped with one filling station set; blend is adjusted thanks to the meter,

3. CNO-DFO blend can be delivered with the second filling station set; volume is controlled by

the meter.

Biofuel Power Generation installation, testing and commissioning

No particular mention is done for the installation of the 3 gensets on their respective site. Bidders

must provide skilled staff for grid and generator installation, testing and commissioning; e.g. engine

preparation, electrical connections to the grid.

Testing and commissioning will be performed with the 30-70 CNO-DFO blend.


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Monitoring


It will be noted the following information:

• Flow sheet: Kg of crushed copra => kg of cake + kg of raw oil

• Nbr. Running hour of the expeller

=> Calculation of: Extraction rate of oil from dried copra (%) = kg raw oil/kg crushed copra

=> Calculation of expeller capacity: = kg crushed copra/nbr. Running hours

• Measuring Means: scale, expeller hour meter

Data indicated in the Oil Mill Logbook

o Date:

o Starting hour

o Stopping hour

o Nbr. Copra bag

o Weight crushed copra

o Weight cake

o Estimated weight CNO


For the 3 gensets it will be noted the following information:

• Accurate measurement of the biofuel consumption in liter

• Nbr. running hours of the generator

• Electrical meter reading (kWh)

=> Calculation of: Consumption in liter/hour

=> Calculation of: Efficiency nbr. kWh/liter biofuel

• Measuring Means: electricity meter, graduated container

Data indicated in the Genset Logbook

o Date:

o Starting hour

o Stopping hour

o Biofuel added in liter

o Electrical meter before starting kWh


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o Electrical meter after stopping kWh


To be noted: Coconut oil has not the same properties as rapeseed oil; therefore, German standard

DIN 51605 cannot be followed but should be adapted to coconut oil specifically (see quality

standard for CNO in annex 2).

The control of CNO samples involves only a few parameters.

With the type of engines selected in this tender, key factors for successful operation include:

- A decrease of the viscosity of CNO.

This is achieved by the use of blends of CNO and DFO,

- A good quality of CNO.

This depends on good copra drying and a controlled milling process. The 3 parameters to

check are the content of: FFA (Free Fatty Acids), water and sediments.

The other parameters are oriented toward the verification of the identity of the oil. In the case of

Abemama, one must not fear a black market of imported unknown vegetable oils.

The CNO samples control will be done by EPU in Tarawa. Testing facilities will be installed and

commissioned in Tarawa at EPU office.

The successful bidder will be in charge to collect and provide to EPU samples of the CNO produces

during the commissioning.

Capacity building

Supplier and / or installer must include provision of capacity building for the personnel that will

operate the biofuel mill and the biofuel power generation.

Bidders must provide consistent description of the capacity building sessions and of their scheduling.

For each section, bidders must provide operation and maintenance (O&M) manuals.


The training will detail the operating condition and safety related to:

• Running operation:

o sorting of copra

o crusher

o oil expeller

o raw oil, settling time, sediments

o first filtration

o final filtration


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o cake collection, time to cool down

o bagging of cake

o use of the filling stations

o appropriate use of tanks

o blending CNO and DFO

• Cleaning and servicing:

o crusher

o oil expeller

o sediments collection

o first filter

o final filter

• Maintenance:

o Crusher: screen, motor, belt,…

o oil expeller: barrels, rings, belt, gears, grease points,…

o first filter: removal

o final filter: pump, plate, pipes, …

o filling stations: hose, pipe, meter

• periodic monitoring and evaluation plan:

The training should include awareness of periodic monitoring and evaluations. A logbook

must be proposed and Trainees will learn how to use it.


The provision of the O&M manuals is a requirement of the contract.

The training will detail the operating condition and safety related to:

• Genset operation:

o Before starting

o Starting procedure

o Stopping procedure

o Engine security

o Priming the fuel system

• Servicing and maintenance:

o Fuel system

o Cooling system

o Lubricating system

o Air filter

o Battery


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• monitoring performance and logbook:

o Performance of a power plant can be monitored by the operator using a log book

which provides for easy recording and clear display of essential information at

regular intervals for engine, generator, operating and metering panels as well as

those relating to critical events affecting the plant. In a rural system where frequent

changes are not encountered, entering the log every day should be adequate.

An example of logbook sheet is given in annex 2.


Coconut oil biofuel is not a diesel fuel and must be used in adapted engines only.

Quality as fuel of coconut oil produced at small scale level is sensitive to copra processing.

Warning on the user’s responsibility and good practices guide should be prepared and

disseminated. It must be noted that, on Abemama, most if not all the copra is sun dried.

Therefore, overcooked copra from dryer fired with biomass is not to fear.

The monitoring of the CNO quality will be carried out by the EPU in Tarawa. Samples of coconut

oil coming from the Final storage tank will be collected and sent to MPWU in Betio.

The training must emphasized the importance of the cleanliness of the bottle where the sample

will be poured.

Performance evaluation

To verify conformity of equipment and performance, the evaluation will be conducted on the oil mill

during the commissioning and staff training period.


Data collected for the monitoring will be used and compared to the technical specification sheets of

each equipment (when applicable).

Mainly:

o Capacity of the shredder/cruscher

o Capacity of the expeller

o Extraction rate of oil from dried copra

o Flow rate of the final filtration


38


Data collected for the monitoring will be used and compared to the technical specification sheets of

each equipment. (when applicable).

Mainly:

o Consumption in liter/hour

o Efficiency; Kwh/liter.

Note: Performance evaluation must be carried out

with the 90-10 CNO-DFO blend.

During one operation day (generally from 6.00 pm to 10.00), and for the 3 gensets.


39

Floor Plan


40


41

Annex 1: example of logbook sheet

DATE …/…/… Starting time :

Engine

Engine hour meter start :

Biofuel supplied to service tank : (litre)

:

Lub. Oil added : (litre)

Battery gravity : Before starting

Generator 1 2 3

Voltage (each phase to neutral):

Amps (each phase):

Frequency: Hz

Electricity meter kWh

Remarks Details of any power interruptions or overloading (time durations, reasons, actions taken, comments). Any defects observed, maintenance required, repair/service

done, equipment, spares used. Comments/reports. Other relevant information

Stopping time :

NAME:

SIGNATURE:


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Annex2: Quality standard for CNO as fuel

Quality standard for Coconut oil as fuel (proposal)

Properties/content Unit Min. Max. Test method

Characteristic properties

Density at 25°C Kg/m3 0,915 - ASTM D1298

Flash Point °C 210 - ASTM D93

Calorific value MJ/kg 37 -

Viscosity (Kin. @ 40°C) mm2/s - 30 ASTM D445

Carbon residue Mass % - 0,40 ASTM 4530

Sulphur content mg/kg - 20 ASTM D5453

Cetane Index 40 - ASTM D4737

Variable properties

Total contamination mg/kg - 25 ASTM 5452

Acid value mg KOH/g - 10 ISO 660

Oxidation stability (110°C) h 4 ASTM D2274

Phosphorous content mg/kg - 15 ASTM D323

Ash content Mass % - 0,02 ISO 6245

Water content Mass % - 0,075 ISO 12937

Source: G. Vaitilingom,J. Cloin. Pacific Regional Bioenergy Workshop 17 – 20 Nov. 2008 in Nadi, Fiji Islands

Documents

PIGGAREP Abemama Island Biofuel Power Generation ......Miriam TIKANA PIGGAREP coordinator for Kiribati MPWU - EPU Mwaati TOROMON MPWU – EPU Beria OROMITA MPWU - EPU Abemama Biofuel