second generation biofuels from oil palm biomass

SECOND GENERATION BIOFUELS FROM
OIL PALM BIOMASS
Loh Soh Kheang and Choo Yuen May
Malaysian Palm Oil Board (MPOB)
18th International Oil Palm Conference
22-25 September 2015
Cartagena, Colombia
PRESENTATION OUTLINE
  Introduction
  Global Development
  Development in Malaysia
  Oil Palm Biomass
 Availability, Energy Characteristics, Application
  Palm Lignocellulosic-Based Second Generation Biofuels
  R,D & C Status, Conversion Efficiency & Potential
Energy Outputs
 Way Forward
  Conclusion
Biomass to Liquid: Bioethanol
Status of Commercial Bio-ethanol Plant from Lignocellulosic Biomass
Company/
Location Beta Renewables Novazyme –
Inbicon /
Crescentino, Italy Technology Pre-treatment - high T
& P, Integrated
Enzymes & PROESA
Eng. Tech. Feedstock Wheat straw, rice
straw, baggase,
corn stover, etc.
biomass used:
270,000 t/yr
Production Project/plant
Status capacity
Cost
(MGY) (USD, mil) 13-20
$159
Operational,
(project) Oct 2013 = 50 mil L
13 MW
electricity
Abengoa
Bioenergy /
Hugoton, Kansas,
USA Enzymatic - custommade enzymes
hydrolysis Multicellulosic
biomass, crop
residue and plant
fibres
25
20 MW
electricity $685 (plant) Construction
expected to
complete,
Dec 2013 Biomass used:
315,000t/yr biomass
Inbicon - DONG
Energy –
Novozymes /
Maabjerg,
Denmark Mechanical
conditioning,
hydrothermal
pretreatment, and
enzymatic hydrolysis. Wheat straw (50 t/
hr)
Pdt: ethanol, biogas,
electricity, fertilizer,
solid biofuel 13-20
$390 - $580 Estimated
(plant) completion,
2016 Biomass to Liquid: Bioethanol
Status of Commercial Biorefinery Plant from Lignocellulosic Biomass
Company/
Location Iogen - Raízen
Energia /
Piracicaba, São
Paulo
Production Project/plant
Status capacity
Cost
(MGY) (USD, mil) Steam explosion bagasse & cane
~13
$100 (plant) Plant startseparate hydrolysis &
straw (fully integrated
up, 4th Q
advanced fermentation into the 1st gen
2014
ethanol )
Technology Feedstock Mascoma - Frontier
Renewable Valero Energy /
Kinross, Michigan,
USA
Consolidated
Wood pulp and chips
bioprocessing -a “dropin” genetically-modified
yeasts
Mitsui (MES) –
Inbicon/Dong–
Teck Guan
hydro-thermal (steam)
pretreatment and
enzymatic hydrolysis
Oil palm EFB
20
$232
Estimated
(construction, completion,
commission 2014/15
and start-up)
1.25 t/day
CAPEX: €10 Operational,
2013
Biomass to Liquid: Bio-oil
Status of Commercial Bio-oil Plant from Lignocellulosic Biomass
Company/
Location Technology Dynamotive,
Guelph, Ontario,
Canada
Fast Pyrolysis
BTG BioLiquids,
Flash pyrolysis
*biorefinery”
Hengelo,
Netherlands
Envergent (UOPEnsyn) - Industria
e Innovazione,
Tuscany, Italy
Envergent (UOPEnsyn) - Tolko
Industries, Alberta,
Canada
Envergent (UOPEnsyn) – Felda
Sahabat, Sabah
Feedstock Wood Chip
Fluidized Bed Reactor
Production
Project/plant
Status capacity (t/day) Cost
(USD, mil) 200
$8.8
Operational,
2007 Wood Residue
120
-
Estimated
completion,
2014 Rapid thermal
processing technology
(RTP)
Mixed pine
forest residues
& demolition
wood
150
-
Expected to
complete,
Dec 2013 RTP
Wood chip &
residue
400
$14.3
Expected to
complete,
Dec 2014 Rotating Cone Reactor
RTP
Palm and
bagasse
residues
(22.5 MGY)
400
$82
150
$45
132,000t/yr EFB
(capital cost)
??
Biomass to Solid Biofuel: Pellet
Status of Commercial Solid Biofuel Production Plant
Company
(Location) Detik Aturan Sdn.
Bhd. (Kuala
Selangor,
Selangor)
Technology Ring die
Feedstock Empty fruit bunch
(EFB)
Felda Palm
Ring die
Industries Sdn. Bhd
( KKS Semenhu,
Kota Tinggi)
EFB
QL Tawau Palm
Pellet Sdn. Bhd.
( QL Palm Oil Mill
1, Tawau)
Flat Die
EFB
GGS-MPOB
briquettes
Piston press
Production
capacity
(t/hr) 6
Project/plant
Cost
(RM, mil) RM1.5 – 2.0 / t
palm pellet
(production cost)
4
RM6.5
(24,000 t/yr)
Status Operational,
Oct 2011
Completed
2011
In operation
4
( 25,000 t/yr)
EFB
1
(37,440t/yr)
RM12.5
(inclusive civil,
building,
electrical and
consultation)
< RM8
Completed
2011
Completed
2010, not in
operation
Renewable Energy
(Biomass Potential in Malaysia)
Renewable Energy
Biomass
Palm
Biomass
EFB
Wood
Sawmill
MSW
Others
Rice
Hydro
Thermal
Rice
Husk
Small
Hydro
Fibre
Shell
POME
Biogas
Solar
Energy
Crops
PV
Jatropha
Algae
Wind
Golden Crop: Oil Palm
Oil Palm Stem
Oil Palm Fruit
Oil Palm Trunk
Palm Frond (Stem, Rachis & Leaves)
Oil Palm – Fresh Fruit Bunch
Basic Facts
•  Fruits per bunch: 1000 to 3000
•  Bunch Weight: 15-25kg
•  Fruit size: 5 cm
•  Fruit shape: Oval
•  Fruit Color: Yellowish Red
•  Fruitlet weight: 10 gm
Empty
fruit
bunch,
EFB
Mesocarp fiber
Anatomy of oil palm fruit
Mesocarp: Palm Oil (PO)
Kernel:
Palm Kernel Oil (PKO)
Shell
Palm shell
Basic Facts
•  Kernel per fruit: 5-8%
•  Mesocarp per Fruit: 85-92%
•  Oil per mesocarp: 20-50%
•  Oil per bunch: 23-25%
Oil Palm Biomass in 2014
No.
Type of Oil Palm Biomass
Amount (mil tonne)
Wet Weight
Dry Weight
OPF (from pruning activity)
OPF (from replanting activity)
-
42.06
3.03
2.
OPT (replanting of 209,200 ha*)
-
3.
EFB (443 palm oil mills, FFB
20.98
processed = 95.38 mil tonnes) =
22% x 95.38 mil tonnes
7.34
4.
Mesocarp fibers, MF (13% )
12.87
7.72
5.
Palm kernel shells (6%)
5.24
4.46
1.
TOTAL
6.
POME generated from per
tonne of FFB is about 65%.
15.58
80.19
63.90
(1789 mil m3
biogas)
3.18**
22.5
(available)
Applications of Oil Palm Biomass
Mulch*
BIO-FERTILIZER
OIL PALM
BIOMASS
* Developed
** Emerging
RENEWABLE
ENERGY
Compost*
Heat and power*
Solid, liquid and gas
bio-fuels **
BIO-COMPOSITE
& BIO-PRODUCTS
MDF**, plywood*,
fibremats*, bio-char**
and activated carbon **
BIO-BASED
CHEMICALS
Sugars/Cellulose, **
lignin**, vitamin E**,
carotenes**, squalene**
SECOND GEN. BIOFUELS – PALM LIGNOCELLULOSIC
BIOMASS
Bioenergy Potential from Oil Palm Biomass (OPB)
BIOMASS TO
GAS (BTG)
BIOGAS
The biogas from
anaerobic digestion of
POME can be used to fire
boilers or run gas
engines to produce
electricity.
BIO PRODUCER GAS
Quality bio-producer gas with
higher heating value (HHV) can
be produced via gasification
using oil palm shell/fibre.
BIOMASS TO SOLID (BTS)
BIO-CHAR
BIOMASS TO
LIQUID (BTL)
COMBINED
HEAT &
POWER (CHP)
BIO-OIL SYNTHETIC DIESEL
Bio-char derived from pyrolysis
or carbonisation process can be
made into:
i. solid fuel
ii. oil /water slurries
iii. activated carbon & soil
enhancer.
Bio-oil from pyrolysis of OPB
can be used for CHP, food
flavoring, chemicals, heat
and steam generation for
small stationary engines, gas
turbines and boilers.
BRIQUETTES/PELLETS
Briquetting of EFB fibre and
palm shell can be conducted
via piston press or screw
extrusion technologies
BIOETHANOL
Production of bioethanol from
EFB/OPT can be carried out via
various different approaches—
chemical, thermal and enzymatic
processes.
SYNTHETIC DIESEL
The synthetic diesel is obtained
from Catalytic Depolymerazation
Process (CDP) of OPB
Baled Solid Biofuels
Long and Short EFB Fibers
•   Cleaned EBF fibers (~10% mc), suitable for exports,
mattresses filler and wood plastic composite.
•   From the same process, the short fibres can be used for
the production of pellets
•   Shredded EFB fibers (~40% mc), suitable for bio-energy
and bio-composite
Independent Biomass Cogeneration Power Plant
Electricity Generation from EFB
– Grid Connected
SEGUNTOR BIOENERGY SDN. BHD.
KINA BIOPOWER SDN. BHD.
Biomass to Solid (BTS)
(Briquettes & Pellets)
Biomass Pellet
Palm biomass briquettes – piston press technology
Charcoal briquettes
Characteristics:
•  Calorific Value 17895 – 18235 kJ/kg
•  Moisture content < 6.0%
•  Ash content < 6.0%
•  Specific Density 1100 – 1300 kg/m3
•  Typical diameter sizes : briquettes Ø < 9cm,
pellet Ø <1cm
Palm Biomass Briquettes – Screw Extrusion Technology
Fibrous EFB & Bale
Torrefied Pellet
Bioethanol Production from EFB
Pretreatment
Hydrolysis
Treated Palm Biomass (Hydrolysate) Mixture of fermenta7on product (bioethanol) Fermentation
Inoculated with microbe Separation
Bioethanol
Op7miza7on study Dis7lla7on at 75°C Fermenta7on in a bioreactor Bioethanol Produc7on from Oil Palm Trunk Dis7lla7on Fermenta7on Purified bioethanol Oil palm trunk sap extrac7on Summary Bioethanol Production from EFB
•   Bisulfite process and formiline pre-treatment (MPOBTsinghua-Shandong University)
•  Optimised ethanol production from EFB:
6 dry tonnes of EFB can produce:
1 tonne of ethanol (17%),
0.8 tonne of high-purity lignin (14%) and
4.2 tonnes of hemicellulosic syrup (70%) as
biochemical feedstock, of which 0.3 tonne of
furfural can be produced (5%)
Bioethanol yield per t dry EFB = 15-25%
Sugar conversion ~75%
Fermentation efficiency ~ 85%
Biomass to Liquid: Bio-oil
Products: - Bio-oil (main), biochar & gas
Bio-oil: biofuel
Biochar: Soil
management/
Carbon
sequestration
MPOB Pyrolysis Experimental Rig
Properties of
bio-oil
Temperature (°C)
400
500
600
Calorific Value
(MJ/kg)
20.23
21.41
21.17
Total Ash, %
0.49
0.65
0.37
pH
3.4
3.0
3.0
Moisture (%)
17.89
18.74
18.21
Density (g/cm3)
1.00
0.90
0.99
Biomass Experimental Kit (BEK)
Gasification of Palm Biomass
Product: - Syngas
Other Gasification pilot plant
Capacity: 30 kW, Fuel: EFB briquettes
•  MPOB in-house technology – pilot scale down-draft fluidized sand
bed gasifier
•  Feed: EFB, palm shell and fiber
•  Process optimization in progress to achieve: H2 (40%); CO (30%);
CH4 (10%)
POTENTIAL BIOGAS UTILIZATIONS IN
PALM OIL MILLS
Co-firing in biomass boiler
Gas engine for electricity
OPTIONS OF UTILIZATION
Diesel Engine (cofiring)
Electricity
Gas Engine
Electricity
Micro Turbine
Electricity
Package Boiler /
Biomass boiler
(cofiring)
Electricity
Steam
Cleaning
potential: 1-2 MW from 60 t/hr mill
282 MW (438 mills)
POME
Cooling
Mixing
Biogas / Methane
Anaerobic
Flare
Aerobic
• Land application
• Composting
• Water course
Biogas capturing technology – cover lagoon and digester tank
Composting / biofertilizer
Off-Site Utilization: Bio-CNG
Raw Biogas
Pretreatment
Compression
CO2 removal
Storage/
dispensing
BioCNG demo plant at Sg Tengi POM, Kuala Kubu Bahru, Selangor
Biogas Capture vs. Methane Avoidance
MPOB-Ronser Zero Discharge POME Treatment System, POMTEC, Labu, Negeri Sembilan
MPOB-BEE High Efficient Methane Fermentation System
Biogas Capture vs. Methane Avoidance
Source: Zulkifli et al., 2015
POMEDfree Zero Waste Technology: 100% nutrients recycling
from POME, sludge, EFB via composting
Way Forward – All-in-One Refinery
Biomass to higher value addition
Biomass
Feedstocks
Starch
Intermediate
Platforms
Hemicellulose
Cellulose
Lignin
Oil
Sugars
Biobased
Syn gas
Glucose, Fructose, Xylose
Arabinose, Lactose, Sucrose, Starch
Aromatics
Gallic, Ferulic
acid, …
Building Blocks
Syn
Gas
H2, methanol & higher
alcohols, oxo and iso-­‐
synthesis products, Fischer-­‐Tropsch
chemicals
•  
C2
Protein
C3
Glycerol, Lactic, 3-­‐Hydroxy
propionate, Malonic acid, Serine
C4
Succinic, fumaric & malic acids, Aspartic acid, 3-­‐
Hydroxy Butyrrolactone, Acetoin, Threonine
C5
Direct
Polymers & Gums
C6
Itaconic acid, Citric/Acotonic
Furfural, Levulinic acid, 5-­‐Hydroxy acid, Glutamic
methyl furfural, acid, Xylonic acid, Lysine, Gluconic
Xylitol/Arabitol acid, Glucaric acid, Sorbitol
Fine chemicals, minor components, products mimic to petroleum counterparts, etc.
Conclusion
•   Huge potential to fully utilise crop residues
of the oil palm industry
•   Successful efforts currently are mainly in
energy and fertiliser applications
•   It is a matter of time when the industry will
move towards higher value applications
with government support
•   The oil palm industry is moving towards
optimal value addition and zero waste
Malaysian Palm Oil Board (MPOB)
Tel : 603-87694400
Fax : 603-89259446
MPOB website: www.mpob.gov.my
Dr. Loh Soh Kheang: [email protected]