Denny K. S. Ng, PhD, MIChemE

• Qualifications: The Biomass Complex in – BEng (Chemical) (Hons.) (UTM) – PhD (University of Nottingham) Palm Oil Industry • Employment History: – Professor of Process Design and Integrated Biorefinery (since 2015) Prof Denny K. S. Ng, MIChemE Associate Professor, University of Nottingham (2012 - 2015) – Assistant Professor , University of Nottingham (2009 – 2012)

– Post-doctoral Research Associate, Texas A&M University, US (2008) Professor of Process Design and Integrated Biorefinery Department of Chemical & Environment Engineering • Areas of research: – Process synthesis & design. – Resource conservation via process integration techniques Founding Director, Centre of Sustainable Palm Oil Research – Biomass processing and integrated biorefineries. (CESPOR) – Energy management The University of Nottingham, Malaysia – Carbon-constrained energy planning

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Outline of Presentation Palm Oil Industry

• Palm Oil Industry World Consumption for Major • Potential, Policy and Challenges Fats and Oils - 2015 palm kernel tallow grease 3% 3% others Palm Oil Production by • Foodsteps of Palm Oil-based Biorefinery lard 11% palm 4% 28% Country - 2015 (Metric – First Generation butter tonnes) 5% Colombia, 1,175,000 • REGEN System to transform Palm Oil Mill sunflower 6% canola soybean Thailand, Nigeria, 15% 25% Others, 2,300,000 970,000 into Palm-based Biorefinery 4,945,000 • Conclusions

Malaysia, Indonesia, 21,000,000 35,000,000

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1 Palm Oil Industry

Oil Palm Planted Area by State (Dec 2014) – Hectares (MPOB, 2015)

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Palm Oil Industry Palm Oil Milling Process

Mesocarp

Sterilisation FFB Kernel Shell Empty Fruit Palm Kernel Shell (PKS) Oil Palm Frond (OPF) Bunches (EFB) Palm Kernel Stripping

EFB HARVESTING OIL MILLING Screw Nut/Fibre Nut Kernel Pressing Separator Cracker Crushing

Fresh Fruit Bunches CPO/CPKO (FFB) Oil Palm Tree Clarification

PMF PKS POME Palm Oil Oil Palm Trunk Palm Mesocarp Palm Oil Mill Purification Crude (OPT) Fiber (PMF) Effluent (POME) Crude Palm oil Palm Kernel Oil IChemE POPSIG 8

2 Crude Palm Oil Production (MPOB, 2015) Potential of palm oil biomass

Biomass available from Quantity % from FFB* Palm Oil Industry (million tonnes) Empty Fruit Brunch (EFB) 23 21.24 Mesocarp Fibre 13 12.00 Palm Kernel Shell 6 5.54 Palm Oil Mill Effluent 60 55.40 (POME)

*Based on 92.33 million tonnes FFB proceed in 2014

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Palm-based Biomass Potential of Palm-based Biomass  By 2020, solid biomass will increase to 85-110 million tonnes, POME to 70-110 million tonnes

Biomass Ultimate Analysis (wt %) LHV Molecular C H N O* (MJ/kg) Formula

Shell 53.78 7.20 0.00 36.30 22.14 CH1.69O0.54

Fiber 50.27 7.07 0.42 36.28 20.64 CH1.61O0.51

EFB 48.79 7.33 0.00 40.18 18.96 CH1.80O0.62

(Extracted from Malaysia Innovation Agency) IChemE POPSIG 11 IChemE POPSIG 12

3 Assessing the best uses of National Biomass Strategy Malaysia’s palm oil biomass 2020

(Extracted from Malaysia Innovation Agency) (Extracted from Malaysia Innovation Agency) IChemE POPSIG 13 IChemE POPSIG 14

National Biomass Strategy Technical Challenges 2020 • Assessing the best uses of Malaysia’s palm oil • Feedstocks: Production, Supply Chain biomass • Capacity, Efficiency: Requires proven – Downstream technologies of today and tomorrow results – Additional value creation: Biomass to wealth • Pellets • Equipment design: Adaption from other • Biofuels industries (e.g., wood) • Biobased chemicals • Technology: Large number of possible • Costing the mobilisation of biomass to create pathways more value from oil palm • Capturing the RM 30 billion opportunity (Agensi Inovasi Malaysia)

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4 Non-technical Challenges

Recent research on palm oil-based biomass • Use of land: Effect of large areas of utilisation (Ng & Ng, 2013)

monoculture Category Technology Value Added Product • Economic: Investment, cost of Physical Densification Palm briquette Palm pellet production, taxation policies, subsidies Hybrid plywood MDF • Company policy/strategy: “wait and see” Biological Anaerobic Digestion Biogas Fermentation Bioethanol • Working environment and culture: Biopolymer Operators are not trained to handle new Compost Thermochemical Gasification Syngas technology Pyrolysis Bio-oil Torrefaction Torrefied biomass Liquefaction Bio-oil IChemE POPSIG 17 IChemE POPSIG 18

Palm Oil-based Biorefinery Platforms of Biorefinery (NREL)

• Processing facility that transform oil palm • Sugar-lignin platform biomass into any value-added products. – Fermentation, hydrolysis, etc. • Thermochemical platform – Biofuels – Gasification, pyrolysis, etc. – Biomaterials • Biogas platform – Specialty chemicals – Anaerobic Digestion – Pharmaceuticals • Carbon-rich chains platform – Biodiesel • Plant product platform – Oil extraction from algae

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5 Integrated Biorefinery Integrated Biorefinery

• Various processing systems (e.g. fermentation, gasification, pyrolysis, hydrolysis etc.) Thermal Chemical Pathway (Gasification, Pyrolysis, etc.) High Value • Focus on the use of non-food crop as feedstocks, Products Clean Gas (Biofuels, e.g. EFB, OPF, OPT, etc.; Biochemicals, Biomaterials, etc.) • Multiple feedstock, multiple products, minimum Biomass Combined Heat & (EFB, PKS, etc.) Power waste

Residuals Bioenergy • Have multiple levels of process integration (Electricity) – Material and energy recovery Biological Pathway (Fermentation, Hydrolysis)

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Footsteps of Palm Oil- Integrated Waste based Biorefinery Recovery & Regeneration System (REGEN System) • Biomaterials • Dried Long Fibre • Palm Briquette • Palm Pellet • Bio-Organic Compost

• Bioenergy • Direct heat & power generation via biomass boiler • Biogas from POME • Electricity

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6 Waste/Biomass → value-added products & power Together with Eureka Synergy Sdn Bhd –

Highly Recommended for Decanter cake Empty fruit bunch Empty fruit bunch Palm oil mill effluent Palm oil mill effluent Palm oil mill effluent Decanter cake Sustainable Technology Award 2015 Empty fruit bunch Empty fruit bunch

Boiler ash

Water Fiberizing Pelletizing Biogas Composting Animal Feed Shortlisted for Recycling System System System System Plant Palm Oil Industry Award 2015 System

Dried Clear Biogas Bio- Animal Pellet Long Fiber Water (power) fertilizer Feed

“together we free DOE from busy schedule in palm oil industry”

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Bioreactor for Biogas Production from Bioreactor for Biogas Production from Palm Oil Palm Oil Mill Effluent (POME) Mill Effluent (POME) Pilot Scale Research The most promising solution for water pollution and energy problems faced by the palm oil industries. 60% SMALLER FOOTPRINT

10% MORE BIOGAS

HIGHER METHANE PURITY

LOWER H2S CONCENTRATION

MEETING BOD 20PPM

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7 IAAB Pilot Plant

Pump House 1 & Pump House 2

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Discharge and Transfer Sump

CESPOR Office and Lab

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8 POME Treatment

Expected Performance

Parameter Treated Recovered DOE Drinking Unit Effluent water Std. Water Std. (2006) pH 6.8-7 7-8 5-9 6.5-9 BOD 15-22 <6 20 6a mg/L COD 200 - 250 <10 Nil 10a mg/L TSS 50-100 400 mg/L Turbidity Nil <5 5 NTU

SCADA System O&G ND ND 50 0.3 mg/L TN 100 mg/L Color -- <15 15 TCU TDS 1000 mg/L abased on raw water IChemE POPSIG 33 34

POME Treatment POME Treatment

Expected Performance Expected Performance Final treated POME via Polishing System

Anaerobic Aerobic treatment treatment

Anaerobically Raw POME treated POME Recovered water from treated POME Average COD: 650 mg/L Average BOD: 28 mg/L Average COD: <10 mg/L Average TSS : 200 mg/L Average BOD: <6 mg/L Average Turbidity : <5 mg/L

abased on raw water 35 36

9 Biogas Generation

Expected Performance Treated POME Parameter Raw Gas Engine Flaring Unit Biogas allowance system Moisture Content 51 10 saturated g/m3

(30-100) or or 4-8 1 %v/v Temperature 40 5 -- oC Methane 60-62 50 10-50b % POME 35a to H2S 40 -700 4000 -- ppm Clear Water 10000a Quality Biogas Production 1200 -- -- m3/hr @STP 800a aevent of failure; b<10% needs burner adjustment Wastewater Water quality After treatment before during treatment treatment IChemE POPSIG 37 38

Fiberizing System

Power Generation System

Product Palm dried long fiber Palm short fiber2 Bulk density 300 kg/m3 -- Fiber length 40 - 45 mm 25 – 30 mm Moisture content 15 % - 35 % 15 % - 35 % Product Power Market price1 (as of May 2014) RM 500 per tonne RM 200 per tonne Capacity (60 t/h FFB) 2200 kW 1The market price quoted is freight-on-board (FOB) price, after Market price (as of October 2014) RM 0.4169 per kW utility cost excluding wear and tear. 2 Palm short fiber is to be recover to pelletizing system for pellet production. IChemE POPSIG 39

10 Pelletizing System Fiber Mat System

Product Fibre Mat GSM 1000 g/m2 Moisture content < 15% Market price1 (as +/- RM 2000 per tonne of May 2014) Product Palm pellet 1The market price quoted 3 is freight-on-board (FOB) 1 Density 650 kg/m The market price quoted is freight-on- price, after utility cost board (FOB) price, after utility cost Heating value 4300 kcal/kg excluding wear and tear. excluding wear and tear. Moisture content < 10.5%

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Biofertiliser System

Product Biofertiliser 1The market price quoted C/N Ratio < 20 is freight-on-board (FOB) Organic Matter > 35 % price, after utility cost excluding wear and tear. Moisture content < 30 % Total NPK > 5 % Market price1 (as of Oct 2014) RM 600 per tonne

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11 Conclusions

• Palm oil mill in Malaysia – Focusing on First Generation Biorefinery/Biogas system only – Development of biorefinery still highly depends on market force • REGEN System – Nottingham Green Technologies Sdn Bhd – Eliminate all solid and liquid wastes – Upgrade the biomass into value-added products

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Acknowledgment

• University of Nottingham New Researcher Fund (NRF 5021/A2RL32) • Eureka Synergy Sdn. Bhd., Malaysia Contact Details: • Havys Oil Mill Sdn. Bhd., Malaysia • Ministry of Higher Education, Malaysia Prof Dr Denny K. S. NG – LRGS Grant (Enhancing Productivity and Sustainability of Palm Oil Milling Industry) [email protected] – LRGS Grant (Future Biorefineries: Unlocking the Potential of Fine Chemicals and Value Added Byproducts)

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