Embed Size (px)
Citation preview
Page 1
Excellent Center of Waste Utilization and Management
(ECoWaste)
Waste Minimization and Cleaner Technology in Agro-industry
Warinthorn Songkasiri, Ph.D.Excellent Center of Waste Utilization and Management (ECoWaste)
National Center for Genetic Engineering and Biotechnology (BIOTEC)7 June 2013
Page 2
Excellent Center of Waste Utilization and Management
(ECoWaste)
Introduction to ECoWaste
1986 BIOGAS LAB
R&D on utilizing agricultural industrial waste to produce biogas.
2006 Change the name to be ECoWaste, an excellence center of BIOTEC and KMUTT lccated at KMUTT Bangkhuntien campus
Page 3
Excellent Center of Waste Utilization and Management
(ECoWaste)
Missions
Research and development on high-rate anaerobic digestion processes and biogas technology to treat and utilize wastes from agro- and food industries and animal farms for renewable energy production and environmental benefits
Biogas Research & Technology DevelopmentWaste Minimization & Production Process Optimization
STAFFS B.S. M.S. Ph.D. Total
BIOTEC 1(1) 6(6) 7(7)
KMUTT 1(1) 4(4) 4(3) 9(8)
Others 5(5) 3(3) - 8(8)
Total 24(23)
Page 4
Excellent Center of Waste Utilization and Management
(ECoWaste)
Wastewater Treatment and Biogas Technology R&D and TT
Chotiwat Manufacturing Co., Ltd.
Rice starch industry�Bangkok Interfood Co.,Ltd.
Tapioca starch industry�Chonchareon Co., Ltd.�Chaiyaphum Plant Co., Ltd.�Northeastern Starch (1987), Co., Ltd.�Sima InterProducts Co., Ltd.�Udonpuempon Co., Ltd.�Asia Fructose Co., Ltd.
Food industry�See-ong Hong Co., Ltd.�Rama Foods Co., Ltd�Chotiwat Manufacturing Co., Ltd.
Page 5
Excellent Center of Waste Utilization and Management
(ECoWaste)
Waste Minimization & Production Process Optimization: Tapioca Starch
Excellent Center of Waste Utilization and Management
(ECoWaste)
Zero Emission
Process Improvement
Hybrid AD
Water reused
Product Quality
Energy
By product Utilized
Biogas
Page 6
Excellent Center of Waste Utilization and Management
(ECoWaste)
Importance of Agricultural Industry
Thailand: Fact and FigurePopulation: 65.4 millionTotal Labor Force: 36.3 million40% of Labor Force in AgricultureTotal Area: 514,000 km2
Agricultural area: 1/3Year 2010 (GDP = 7.8 %)
GDP Composition by Sector (2009) Labor Force by Occupation
Agriculture: 11 %Services: 55 %Industries: 34 %
Agriculture 40 %Services 43 %Industries 17 %
Source: BIOTEC, 2012
Page 7
Excellent Center of Waste Utilization and Management
(ECoWaste)
Economic and Social Indicator: Food and Agriculture in 2010
Export value of agri- and food products ∼ 800,000 million baht• 12% of Thailand total export value• 2.4% of world market
The 7th largest world agricultural and food exporter
• apart from EU US Brazil China Canada and Argentina
• 91% are small and medium enterprises for domestic consumption• 9% are medium and large companies for export
Food Processing Plant ∼ 10,159 plants
Source: BIOTEC, 2012
Page 8
Excellent Center of Waste Utilization and Management
(ECoWaste)
69 factories are native starch producers and 11 factories are native and modified starch producer
Northeastern (46%), Eastern (31%), Central Plain (15%), Northern (8%)
Industry of Interest: Tapioca Starch Industry
0
5,000
10,000
15,000
20,000
25,000
30,000
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Expo
rt Va
lue (M
illion
Bah
t)
Year
Export value statistics of tapioca starch in 2001-2011
Native Starch Modified Starch Sago
Cassava products : world ranking 1, market share 34%
Page 9
Excellent Center of Waste Utilization and Management
(ECoWaste)
Native StarchUS$ 0.9 billion
Modified StarchUS$ 0.4 billion
1 million employees
Chips and PelletsUS$ 0.8 billion(price US$150 /ton)
StarchUS$ 1.3 billion
0.02 million employees
Value-added Industries> US$ 8.5 billion
2.4 million employees
Cassava Stem CuttingUS$ 0.2 billion
Fresh Cassava rootUS$ 1.4 billion
(price US$ 55 /ton)
Value Chain Analysis of Thailand Cassava Industry in 2008
Page 10
Excellent Center of Waste Utilization and Management
(ECoWaste)
Root Receiver
Washer/Cutter มีดสับ
Rasper
Coarse Extractor
Tapioca Starch Production Process
Excellent Center of Waste Utilization and Management
(ECoWaste)
Page 11
Excellent Center of Waste Utilization and Management
(ECoWaste)
Resource Utilization in the Production Process
Source: BIOTEC, 2012
Resource use/ton starch producedSize 0f starch factory
small medium largeCassava root (ton) 4.22-4.28 3.70-3.80 3.7 water (cubic metre) 11.41-12.16 7.52-9.97 7.40-10.75 Starch recovery (%) 72.0-75.0 75.0-76.0 77.9electricity (kilowatt-hr) 150-163 117-125 145-147 Fuel oil (L) 32.6-36.6 28.9-32.9 33.7-36.4 Wastewater (cubic M.) 12.8-16.3 8.5-10.9 10.9-11.9 Cassava pulp (kilogram) 937-945 980-1,180 1,002-1,090 Starch loss in wastewater (%) 2.0-4.0 1.0-2.0 5.0-6.0Starch loss in pulp (%) 12.0-13.0 13.0-15.4 17.0-23.0Sulfur (kilogram) 0.4-1.0 0.7-0.8 0.9Drying efficiency (%) 60-74 76-82 62-65Other solid residues (kilogram) 105.1-161.0 140.0-151.6 131.0-205.8
Starch loss in solid residue (%) 1.0-2..0 2.0-3.0 2.0-3.0Starch loss in drying (%) 8.0-9.0 2.0-6.0 1.0-3.0
Page 12
Excellent Center of Waste Utilization and Management
(ECoWaste)
% S
tarch
Yiel
d
200 to 212.5 tons/dayEq. 1.06 tonEq. 1 ton
Aiming to Increase Starch Yield
Page 13
Excellent Center of Waste Utilization and Management
(ECoWaste)
Priorities and Approaches
Excellent Center of Waste Utilization and Management
(ECoWaste)
R&D and Dissemination
• Knowledge & technology
• Demonstration (Zero discharge starch factory)
Capacity Building
• Training/curriculum
• 3 target groups – industry, consultant, engineering graduates
• Starch Engineering and Process Optimization Program (SEPO)
Industrial Standard
• Collaboration with other government agencies/private sector/assoications
• Department of Industrial Promotions, GIZ, factories
Page 14
Excellent Center of Waste Utilization and Management
(ECoWaste)
R&D and Dissemination
Root Receiving
Extracting Separating
Rasping
Dewatering Packaging
- Mechanistic study of each unit process- Study of affecting parameters (feed, design, and
operating variables)- Lab-scale to Pilot-scale to applying to Industrial-scale
machine
Rasping
Page 15
Excellent Center of Waste Utilization and Management
(ECoWaste)
Mechanistic Study of Extraction UnitPulp Starch slurry
Pulp Starch slurry
pulp
starch
Starch Slurry
Pulp
Pulp Extractor #1, 2, 3
� Filtration area = 1.23 m2
� Rotational speed = 1200 rpm
� Screen aperture = 80 mesh (0.177 mm)
Page 16
Excellent Center of Waste Utilization and Management
(ECoWaste)
Starch Loss with Cassava Pulp During Extraction
Feed variable
• Liquid/Solid (L/S) ratio• Crushed size of tapioca root
Design variable
• Basket radius & Area• Screen aperture
Operating variable
• Rotational speed• Volumetric feed flow rate
Fiber
Starch
Grinded tapioca root Conical-screen extractor
Page 17
Excellent Center of Waste Utilization and Management
(ECoWaste)
1717
Affecting Factor Author, Year Condition Experimental Result
L/S ratioC. Siriwattanachai-kul, et al., 1997
- ω 200 rpm- L/S ratio 4-20
- Separation efficiency increased as L/S ratio increased from 4 to 6- L/S ratio over 6, yielded constant of separation efficiency
Crushed size of tapioca root
N. Piyatamrongrat, 2005
- L/S ratio 10 - Small crushed size of tapioca root (0-179 µm) provided highestseparation efficiency
Basket angle K. Lorsubkong, 2007- Basket 30°-75°- ω 1,100 rpm- Screen 35 mesh
- 45° provided highest separation efficiency
- 30° increased the mass of deposited cake on screen, while 60° and 70°decreased the retention time of cake on screen
Basket area(smooth, rough)
W. Sasadoor et al, 2005
- Basket 72°- L/S ratio 10.7
- Screen 35 mesh
- Rough basket increased the retention time of cake on screen, resulting in an increase in water removable efficiency
Water injection angle
W. Wisitrungraung, 2005
- 60°, 90°, 120°- ω 1,400 rpm- Velocity 0.6 m/s
- 120° provided the highest separation efficiency due to the facilitation of driving force acting on screen
Screen aperture P. Sarochsuwan, 2009 - Screen 70-90 mesh- large screen aperture enhanced filtration and separation efficiency,however there would be more fiber in filtrate
Rotational speedP. Thanomsaksri,
ω
- Separation efficiency increased as rotational speed increased due to therise in centrifugal force
Affecting Parameters during Extraction
Page 18
Excellent Center of Waste Utilization and Management
(ECoWaste)
Pilot Scale Experiment on Extraction
Rw
PA
RR
PAQ
c µαµµ +∆=
+∆=
)(
Page 19
Excellent Center of Waste Utilization and Management
(ECoWaste)
Mechanistic Study of Extraction Process
Effects of rotational speed on cake thickness and cake solidosity at various basket radii
Page 20
Excellent Center of Waste Utilization and Management
(ECoWaste)
Mechanistic Study of Extraction ProcessEffect of rotational speed on starch separation efficiency at various basket radii
Page 21
Excellent Center of Waste Utilization and Management
(ECoWaste)
Mechanistic Study of Extraction Process
Page 22
Excellent Center of Waste Utilization and Management
(ECoWaste)
Knowledge from Research Topics on Tapioca Starch Production ProcessWater•Water Recycle from Wastewater Treatment System to the Starch Production Process•Water Reuse between Individual Starch Processing Units•Effects of Process Water Characteristics on the Quality of Starch ProductExtraction•Effects of Angles and Velocities of Injected Water on the Extraction Process in the Native Cassava Starch Production•Effects of Centrifugation and Filtration on Tapioca Starch Extraction EfficiencySeparation•Loss Reduction and Starch Recovery from the Light-Phase Fluid in the Separation Process•Feasibility Study for the Replacement of Separator with Hydrocyclone•Enhancement of Tapioca Starch Collection by Post CycloneDrying•Development of Starch Moisture Content Controller in the Drying Process•Predictive controlling model for the tapioca starch drying process•Factors influencing on amount of oversize cassava starch generation during pneumatic conveying drying
Page 23
Excellent Center of Waste Utilization and Management
(ECoWaste)
Knowledge Dissemination: Zero Waste Concept to 6 Factories
KPI(per ton starch dry basis)
Range Median Before improvement
Afterimprovement
Cassava Roots (KPI-1) 3.70 – 3.86 tons 3.78 6.69 5.48
Water consumption (KPI-5) 7.5 – 10.8 m3 9.15 8.99 8.12
Electricity (KPI-4) 110 – 117 kW-hr 113.5 152.8 -
Sulphur 0.3 – 0.4 kg 0.35 0.55 0.53
Wastewater 8.5 – 10.9 m3 9.7 7.55 7.21
Starch loss with WW (KPI-1) 0.08 – 0.20% 0.14 2.25 (Lab) 2.23 (Lab)
Cassava Pulp 0.500 – 0.937 tons 0.719 0.60 0.58
Starch loss with pulp (KPI-1) 1.9 – 2.4% 2.15 5.00 (Lab) 2.67 (Lab)
Starch yield (KPI-1) 77.9 – 92.0% 84.95 77.61 83.25
Process improvement for all unit processes in the factory
Page 24
Excellent Center of Waste Utilization and Management
(ECoWaste)
Priorities and Approaches
Excellent Center of Waste Utilization and Management
(ECoWaste)
R&D and Dissemination
• Knowledge & technology
• Demonstration (Zero discharge starch factory)
Capacity Building
• Training/curriculum
• 3 target groups – industry, consultant, engineering graduates
• Starch Engineering and Process Optimization Program (SEPO)
Industrial Standard
• Collaboration with other government agencies/private sector/assoications
• Department of Industrial Promotions, GIZ
Page 25
Excellent Center of Waste Utilization and Management
(ECoWaste)
Knowledge to Curriculum - Capacity Building in Tapioca Starch Industry
Curriculum on Resource and Energy Efficiency 2009-2011 Training course and workshop for industrial
personnels, consultants, and engineers (Lecture and 4-month OJT; 413 participants)
2012-2015 Training course and workshop for 30 factories (Lecture and 4-month OJT; 84 participants from 10 factories in 1st year)
Page 26
Excellent Center of Waste Utilization and Management
(ECoWaste)
April May June
Training Course / Workshop
July August September October November
Project PR and Application
On-the-Job Training at Factories (Teams of factory, consultant, project’s experts)
December
Curriculum Date
Factory (Executives) 2 days in July
Factory (Staffs) 6-8 days in July and August
Presentation Date
Proposal August
Progress September
Final October
2 Levels: Executives and Personnels
Capacity Building in Tapioca Starch Industry
Page 27
Excellent Center of Waste Utilization and Management
(ECoWaste)
Impact from the NSTDA-GIZ Collaboration Project
15 cassava starch factories participated in OJT
Loss reduction of 112 million baht/year
• Reduction of starch loss in process 5,735 tons/year
• Reduction of water use 692,640 m3/year
• Reduction of Fuel use 1,147 tons of fuel oil equivalent/year
Improvement of Water Injection in Extractor Design of Sieve Effect of Screen Aperture of Extroctor
Page 28
Excellent Center of Waste Utilization and Management
(ECoWaste)
Starch Engineering and Process Optimization Program (SEPO)
SEPO was established in 2004
Offer full scholarship for Master degree students
In the area of Food Engineering, Chemical Engineering, Bioresources and biotechnology
1 Year 1 Semester 1 Semester
Academic training(ChEPS or FEPS)
IndependentResearch
(on tapioca starch)
IndustrialResearch(Internship)
Page 29
Excellent Center of Waste Utilization and Management
(ECoWaste)
Priorities and Approaches
Excellent Center of Waste Utilization and Management
(ECoWaste)
R&D and Dissemination
• Knowledge & technology
• Demonstration (Zero discharge starch factory)
Capacity Building
• Training/curriculum
• 3 target groups – industry, consultant, engineering graduates
• Starch Engineering and Process Optimization Program (SEPO)
Industrial Standard
• Collaboration with other government agencies/private sector/assoications
• Department of Industrial Promotions, GIZ, factories
Page 30
Excellent Center of Waste Utilization and Management
(ECoWaste)
Industrial Standard through Key Performance Indices (KPI)
KPI 1ประสิทธิภาพ
(%)
KPI 1/1แป้งในกาก
KPI 1/2แป้งในนํ _าเสีย
KPI 2ก๊าซชีวภาพ
KPI 5ปริมาณนํ _าทีiใช้
KPI 4ปริมาณไฟฟ้าทีiใช้
KPI 6พลังงานทีiใช้อบแห้ง
เผาทิ Sง
กากแห้ง /กากเปียก
กฟภ.
KPI 3ก๊าซชีวภาพ /ภาระอินทรีย์
บ่อบําบัด
นํ Sาดิบ
เชื Sอเพลงิอืeน
โรงไฟฟ้า
ต้นทุนการผลิต
Page 31
Excellent Center of Waste Utilization and Management
(ECoWaste)
Industrial Standard: KPI1 Total Starch Yield
0%1%2%3%4%5%6%7%8%9%10%11%
0%10%20%30%40%50%60%70%80%90%
100%
ธ.ค.-52ม.ค.-53ก.พ.-53มี.ค.-53เม.ย.-53พ.ค.-53มิ.ย.-53ก.ค.-53ส.ค.-53ก.ย.-53ต.ค.-53พ.ย.-53ธ.ค.-53ม.ค.-54ก.พ.-54มี.ค.-54เม.ย.-54พ.ค.-54มิ.ย.-54ก.ค.-54ส.ค.-54ก.ย.-54ต.ค.-54พ.ย.-54ธ.ค.-54ม.ค.-55ก.พ.-55มี.ค.-55เม.ย.-55พ.ค.-55มิ.ย.-55
สัดส่ว
นแป้ง
ทีeสูญ
เสีย
(%)
ประส
ิทธิภา
พกร
ะบวน
การผ
ลิต (%
)สัด
ส่วนแ
ป้งใน
หัวมัน
สาํปะ
หลัง
(%)
KPI 1 ประสทิธภิาพกระบวนการผลติรวม
KPI-1 ประสิทธิภาพรวม สัดส่วนแป้งในหวัมนัสําปะหลงั KPI 1/1 สัดส่วนแป้งทีiสูญเสียทีiกากมนั KPI 1/2 สัดส่วนแป้งทีiสูญเสียทีiนํ _าเสีย
88.3%84.1%
Page 32
Excellent Center of Waste Utilization and Management
(ECoWaste)
Industrial Standard: KPI1 Total Starch Yield
KPIMEDIAN BMI 1
(2554)
MEDIAN BMI 2
(2555)Factory A
KPI 1 (%) 86.63% 86.78% 80.88%
KPI 1/1 (%) 4.73% 4.03% 15.93%
KPI 1/2 (%) 1.22% 1.13% -
KPI 2 (m3 biogas/ton starch) 93.37 92.75 -
KPI 3 (m3/kg COD removed) 0.57 0.58 -
KPI 4 (kWh/ton starch) 223.53 220.76 174.28
KPI 5 (m3 water/ton starch) 18.27 16.41 48.53
KPI 6 (MJ/ton starch) 1,698.14 1,640.23 1,561.44
Page 33
Excellent Center of Waste Utilization and Management
(ECoWaste)
Resource Utilization in the Production Process (1990s-2000s)
Source: BIOTEC, 2012
Resource use/ton starch producedSize 0f starch factory
small medium largeCassava root (ton) 4.22-4.28 3.70-3.80 3.7 water (cubic metre) 11.41-12.16 7.52-9.97 7.40-10.75 Starch recovery (%) 72.0-75.0 75.0-76.0 77.9electricity (kilowatt-hr) 150-163 117-125 145-147 Fuel oil (L) 32.6-36.6 28.9-32.9 33.7-36.4 Wastewater (cubic M.) 12.8-16.3 8.5-10.9 10.9-11.9 Cassava pulp (kilogram) 937-945 980-1,180 1,002-1,090 Starch loss in wastewater (%) 2.0-4.0 1.0-2.0 5.0-6.0Starch loss in pulp (%) 12.0-13.0 13.0-15.4 17.0-23.0Sulfur (kilogram) 0.4-1.0 0.7-0.8 0.9Drying efficiency (%) 60-74 76-82 62-65Other solid residues (kilogram) 105.1-161.0 140.0-151.6 131.0-205.8
Starch loss in solid residue (%) 1.0-2..0 2.0-3.0 2.0-3.0Starch loss in drying (%) 8.0-9.0 2.0-6.0 1.0-3.0
Page 34
Excellent Center of Waste Utilization and Management
(ECoWaste)
Tapioca Starch Network
www.thailandtapiocastarch.net
Page 35
Excellent Center of Waste Utilization and Management
(ECoWaste)
Priorities and Approaches to Sustainable Tapioca Industry
R&D and Dissemination
• Knowledge & technology
• Demonstration (Zero discharge starch factory)
Capacity Building
• 3 target groups – industry, consultant, engineering graduates
• Training/curriculum
• Starch Engineering and Process Optimization Program (SEPO)
Industrial Standard
• Collaboration with other government agencies/private sector/assoications
• Department of Industrial Promotions, GIZ
Impact on Productivity, Environment, and Industry’s Competitiveness
Page 36
Excellent Center of Waste Utilization and Management
(ECoWaste)
Excellent Center of Waste Utilization and Management (ECoWaste)
Dr. Warinthorn Songkasiri
Address: Excellent Center of Waste Utilization and Management (ECoWaste)
PDTI Building, King Mongkut’s University of Technology Thonburi (Bangkhuntien)
49 Soi Tiantalay 25, Thakham, Bangkhuntien, Bangkok 10150 Thailand
Telephone number: (668)6909-4210
Fax number: (662)452-3455
Email address: [email protected]
Contact
Excellent Center of Waste Utilization and Management
(ECoWaste)
36
