Date : 21st April 2011 Venue : PNB Darby Park, KL - Biomass-SP

Date : 21st April 2011
Venue : PNB Darby Park, KL
PRESENTATION STRUCTURE
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FRIM
Paper Mill Sludge Pellet
Drum Method for Carbonization
Rice Straw Pellet System
HTD for Rubberwood and Tropical
Hardwood
Conclusion
FRIM
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Established 1929
Statutory body
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Malaysia Forestry Research and
Development Board under the Ministry of
Primary Industries in 1985 (Act 319)
In 2004, moved to Ministry of Natural
Resources and Environment
Carry out R, D & C across the forestry
value-chain
FRIM
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Five research divisions:
• Forestry
• Product Development
• Biotechnology
• Natural Products
• Conservation of Forest Biodiversity
With 5 other supporting divisions.
Vision & Mission
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Vision
To make FRIM a world-class tropical
forest research institute
Mission
To achieve excellence in scientific
research, development and forestry
services
Pellets from Paper Mill Sludge
Forest Product
Division
Industry
Sector
Phase of
Project
Development
Renewable
Energy
R&D
Completed*
Puad Elham
Ahmad Sharafi
Othman
Shamsuri Mohd Som
Nordin Puteh
PELLETS FROM PAPER MILL SLUDGE
INTRODUCTION
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Malaysia,
• 1 million metric tonnes of sludge generated
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Innovation
• Industrial Sludge
Fuel Pellets
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Recycling Industrial fiber wastes into briquettes
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Environmentally Friendly Product can be widely used in
industry – boiler feedstock
PELLETS FROM PAPER MILL SLUDGE
THE INNOVATION
• Producing Pellets from sludge ----
Environmentally friendly method of disposing
sludge
• Pellets = converting loose material (saw dust) into
a compact shape sans binder through compression
• Creates a new opportunity for the paper industries
Uniqueness
• Penggunaan 100% bahan enap cemar kertas
• Pembuatan produk pellet yang di hasilkan
kepada saiz yang diperlukan.
• Produk alternatif kepada kayu sebagai bahan
bakar
• Mengeksploitasi penggunaan bahan enap cemar
yang terhasil sebagai bahan produk nilai tambah.
Flow Chart
EC Pellet
Bahan enap cemar
Proses pengeringan
Campuran
EC 70:30 50:50
Kandungan lembapan (%)
7.5
4.0
4.3
Ketumpatan (kg/m3)
150 1223
1176
Bahan meruap (%)
52.1 67.4
62.9
Kandungan abu (%)
40.1 21.8
16.5
Kandungan karbon (%)
7.8
10.8
20.6
Kandungan kalori (MJ/kg)
5.2
11.7
13.1
Proses pemampatan
EC pellet
Advantages
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Bersih dan mudah dikendalikan
Mempunyai ketumpatan yang lebih tinggi
Mempunyai bentuk dan saiz yang seragam
Meningkatkan lebih daripada 10 isipadu sisa
Tempoh penyimpanan lebih lama
Pembakaran yang sekata dan lengkap
Membuka peluang yang menguntungkan kepada
industri kertas yang menghadapi masalah
pelupusan bahan enap cemar.
• Kaedah pelupusan yang mesra alam.
Drum Method for Carbonization
Forest Product
Division
Industry
Sector
Phase of
Project
Development
R&D
Completed
Puad Elham
Renewable
Energy
Commercial
Ready
Introduction
• Charcoal is a carbonaceous solid with a fixed
carbon content of 70% or more
• The drum method is suitable for the production of
coconut shell charcoal.
• The major drawback is the emission of large
quantity of smoke and tar during carbonisation
process which makes it environmentally
hazardous
• The other problems pertained to the quality and
uniformity of the charcoal produced
Innovation
• Charcoal in a Simple, Quick, Efficient, and
Economic kiln.
• reduce emissions and its greenhouse effect.
• It also and can be constructed in a suitable sizes
by local materials.
• Environmentally friendly, productive and
economical for charcoal production in Malaysia
Advantages
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Clean and easier handling
Complete carbonisation
Efficient – quality & quantity
Low cost
Environmental friendly
Comparison
Carbonisation (hours)
Charcoal (kg)
Efficiency (%)
Cost (RM)
Moisture content (%)
Volatile matter (%)
Ash content (%)
Fixed carbon (%)
Calorific value (MJ/kg)
EFDM
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40
60
6.1
12.4
2.3
85.3
32.7
Drum
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18
20
50
12.5
21.0
2.5
76.5
31.0
Products
Rice Straw Pellet
Forest Product
Division
Industry
Sector
Puad Elham
Ahmad Sharafi
Othman
Shamsuri Mohd Som
Nordin Puteh
Phase of
Project
Development
R&D Completed
Renewable
Energy
Patent Filed
(PI2011000230)
Commercial
Ready
Introduction
• Rice straw is the dry stalks of rice plants, after
the grain and chaff have been removed.
• More than 1 million tonnes of rice straw are
produced in Peninsular Malaysia annually.
• Burning in the open air is the common technique
of disposal that contribute to air pollution.
Process
• Pellets are a type of solid fuel, generally made
from compacted residues.
• Pellets are produced by compressing the
residues which has first passed through a crusher
to provide a uniform mass.
• They are usually produced as a byproduct of
agricultural activities.
• The pellets are extremely dense with low
moisture content that allow them to be burned
with very high combustion efficiency.
Properties
Straw
Wood
Oil palm
Moisture content (%)
7.5
7.5
5.9
Volatile matter (%)
71.3
82.8
88.2
Ash content (%)
12.8
1.2
4.2
Fixed carbon (%)
8.4
8.5
1.6
Density (kg/m3)
1060
1265
982
Calorific value (MJ/kg)
15.8
19.1
19.7
Advantages
• Uniform in size and quality
• Easy to transport and store
• The process increases the net calorific value of
material per unit volume
• The process often helps to solve the problem of
residues disposal
• The process helps to reduce deforestation by
providing a substitute for fuel wood
Process of EFB for Biodegradable Container
Forest Product
Division
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Industry
Industry
Sector
Sector
Dr. Rushdan Ibrahim
Nurul Husna Mohd
Hassan
Latifah Jasmani
Salmiah Ujang
Eco-Products ;
Environmental
Services
Renewable
Energy
Phase of
Project
Development
R&D
Completed
Commercial
Ready
Samples sent
to customer
Introduction
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In Malaysia, food containers, industrial packaging
and medical utensil are mostly made from plastic
either from polylactide (PLA) or polyethylene
terephthalate (PTE).
Products made from plastic are not
environmentally friendly due to their difficulty in
composting, and costly due to the escalating
price of petroleum.
In developed countries, these products are made
from lignocelluloses fibres that are
biodegradable.
Agricultural Residues
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Malaysia is blessed with abundant supply
of natural fibres.
There are million of tones of agricultural
residues that can be used as a raw
material to produce such moulded pulp
packaging products.
Moulded pulp packaging is made from pulp
which is moulded into a shape designed to
hold and protect the products to be packed.
Oil Palm Biomass
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Oil palm biomass, the most abundant fibre resource, is
readily available from existing oil palm plantations and
palm oil mills.
Each year, the oil palm industry generates approximately
13.9 million tonnes of moisture-free cellulosic materials
to act as renewable and permanent feedstock raw
material for the production of paper pulp.
Thus, oil palm biomass that includes oil palm trunk
(OPT), oil palm fronds (OPF) and empty fruit bunches
(EFB) could become supplementary fibre sources of
short-fibered pulps that traditionally has been produced
from hardwoods.
Flowchart
Examples of moulded products can be made by oil
palm biomass.
HTD System for Rubberwood and Tropical
Hardwood
Forest Product
Division
Industry
Sector
Choo Kheng Ten
Phase of
Project
Development
R&D Completed*
Eco-products
Patent Filed
(PI2010002410 &
PCT/MY2010/000287)
Sik Huei Shing
Ramzul Iklas Ab Lah
Environmental
Services
Commercial Ready
DESCRIPTION OF THE TECHNOLOGY
Description of Product (s)
THE ESSENTIAL SYSTEM FEATURES CONSISTS OF,
• Main HTD Chambers built-up of proprietary K-Block panels- light
weight with sufficient stiffness to limit deformation under high
temperature.
• The handling line is a platform trolley holding timber packs which are
forklift-loaded.
• A physical restraint protocol is also incorporated to ensure quality
throughput of lumber batches.
• The humidification system to provide both the steam spray and water
spray (at ambient temperature) which are essential stages of HTD
protocol.
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Con’t… Description of product
• Pneumatic control ventilation system.
• Industrial PLC (programmable logic controller)
instrumentation which coordinates the monitoring and
controlling of various parameters as specified by the HTD
protocol
• Uniform cross-flow air circulation through timber stacks at
high speed of 2.5 to 3.5 m/s
IBS HTD STRUCTURE
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IBS HTD STRUCTURE
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Properties of HT-dried Rubberwood
Reduced warping in timber
Better
dimensional
stability
Enhanced
grain feature
Slight increased in specific strength
MANUFACTURING ASPECT
Production Volume
14 ton per kiln per 1-day cycle
• 1,260 ton per month
• 15,120 ton per year
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Standard and Regulation
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Compliance with EU Directives
– Categorisation of borates under “Reprotoxic Category 2”
under the Dangerous Substance Directive (67/548/EEC)
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PROPOSED SELLING PRICE & MANUFACTURING COST
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COMPARISON WITH AVAILABLE PRODUCT IN THE MARKET
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Proposed Selling Price
Manufacturing Cost
Profit Margin
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Custom HT-Drying Service Charges
Proposed Service Charges about RM 300/t
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Customised HTD System Package
Proposed Selling Price RM 5-6 million per package
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RM 1,430/t
RM 1,267/t
RM 163/t
MARKET POTENTIAL
WHAT ARE THE MARKET SIZE – LOCAL & INTERNATIONAL
Current Drying Practice in Malaysia
95%
5%
Conventional
System
(Temp < 80 degC)
Others
Source: MTIB
Targeted replacing 40% of existing conventional system in Malaysia
Midterm, TWI will explore the export market in the Asia Pacific Region
especially Indonesia, Vietnam, India and China.
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WHAT IS THE ADVANTAGE/DISADVANTAGE
Some of the much improved attributes arisen from FRIM innovation are,
Reduced negative impact on the environment
HTD system offers an alternative solution to use of chemical preservative
borates via use of high-heat treatment technique.
Energy-efficient system
The HTD time for 30 mm-thick sawn dimension stocks is reduced to
about 2 days compared to conventional drying which requires 14-16 days.
Cost-efficient operation
A techno-economic study shows that a complete HTD plant can be set
up with a capital investment comparatively less than that required for
setting up a conventional drying plant. The comparisons are based on
the same overall production capacity, designed for both types of kiln
system.
Enhanced timber quality
• Minimise warping via a physical restraint protocol to maintain a
straight-form sawn timber.
• Enhanced wood grain feature and a more uniform albeit darker
colour throughout the lumber.
• Increased dimensional stability - has lower equilibrium moisture
content (EMC), less movement (shrink and swell due to
fluctuating ambient moisture) under general service condition.
PHOTO OF THE PROTOTYPE
HTD SYSTEM
Products produced from HT-dried rubberwood
CONCLUSION
HTD the solution to chemical free rubberwood
Environmentally friendly
Cost-effective
Just in time (JIT) stock holding
Energy efficient
Enhanced timber quality
Ensures Malaysia’s continued dominance in the
rubberwood industries.
Bil
Researcher
Division
Title of Invention
1
Puad Elham
Forest Products
2
Mohd Nor Mahat
Forestry Biotechnology Torrified Acacia Wood As Bio-Coal (FRIM TRAW)
3
Abdul Rashid Li
Natural Resources
Products
Pectin-Rich fraction of Morinda Citrifolia as
glucose lowering agent
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Dr Rushdan Ibrahim
Forest Products
Converting oil palm empty bunches into all types
of alkaline pulps for different types of paper
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Dr Nor Azah Mohamad
Natural Products
Ali
Natural based essential oil product with potential
adulticidal effects
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Mohd Shahidan Mohd
Natural Products
Arshad
Standardised Tinospora Extract (Tinosporex™)
with anti-hypercholestrolemic property
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Dr Mohd Khairun
Anwar Uyup
Phenolic-Treated Plybamboo (PTP)
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Dr Nor Hasnida Hassan Forestry Biotechnology
Natural Products
Versatile Charcoal Briquette Machine
Induction of hairy root culture from Tongkat Ali
explants using Agrobacterium rhizogenes
Bil
Researcher
Division
Title of Invention
9
Dr Nor Hasnida Hassan
Forestry Biotechnology
Production of Tongkat Ali bioactive
compounds from hairy root culture
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Dr Hasnida Hassan
Forestry Biotechnology
Micropropagation of Tongkat Ali using
tissue culture techniques
In vitro propagation of Aquilaria hirta
(Chandan) using tissue culture
techniques
Micropropagation protocol of Mas
Cotek (Ficus deltoidea)
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Dr Hasnida Hassan
Forestry Biotechnology
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Dr Hasnida Hassan
Forestry Biotechnology
13
Dr Wan Tarmeze Wan
Ariffin
Forestry Biotechnology
14
Dr Hasnida Hassan
Forestry Biotechnology
15
Dr. Wan Tarmeze Wan
Ariffin
Forestry Biotechnology
Enginneered lumber from crushed and
dismantaled bamboo material
Forest Biodiversity
ECfC 06: a standardized extract of
Erythroxylum cuneatum forma
cuneatum (Miq.) Kurz (cinta mula) as
herbal remedies for addition therapy.
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Dr. Mohd. Ilham Adenan
Bamboo-Oil Palm hybrid Engineered
Lumber (B-POPS™)
In vitro propagation of Aquilaria
malaccensis (Karas) using tissue culture
techniques