Sustainability in Palm Oil Processing Industry
28
Sustainability in Palm Oil Processing Industry 26 Oct 2021 Yung Yen Li
Transcript of Sustainability in Palm Oil Processing Industry
Sustainability in Palm Oil Processing
Industry
26 Oct 2021
Yung Yen Li
Contents1. Systematically minimise energy wastage at the mills
• Renewable energy from 60 t/h palm oil mill
• Palm Oil -- potential from POME
2. Utilities saving at refinery
• Vent economizer, Heat recovery, Condensate utilization
• Inverter, LED light, RO water recycling, Effluent water recycling
3. Green energy/ initiatives
• LNG replaces diesel
• GHG monitoring - by product stream
• Biomass boiler & improvement, Bio lubricant
4. Emission Control measures
• KCP Dust Plants
• Boiler Wet scrubber & ESP
Renewable energy from 60 t/h palm oil mill
FFB t/h 60 1,440
POME m³ 42 1,000
Biogas Nm³ 1,260 30,000
1 m³ of POME generate 30 Nm³/d biogas
Methane % 60
COD ppm 60,000
Electric power MWh 2 48
Water resource
Pre
tr
eatm
en
t
Facultative & aerobic digestion ponds
Compressed biogas
• Boiler fuel
• Online motor fuel
• Other uses
Biogas
Closed anaerobic pond
Gas engine
Compressor
Prof. Dr. Mukesh [email protected] : +91 93226 54705
Jul 27, 2021, Forbes
Glenfiddich Is Now Using Whisky
Waste To Power Its Trucks
Palm Oil has the potential to do the
same with its POME
At Kunak, Sabah
Inventor – Modified Horizontal SterilizerIr. Krishna Moorthy,[email protected]
Creating Value from Biomass
Mill solid waste fired 42 MWth
Boiler Losses18 MWth
Boiler
20 bar
η = 0.56
Exhaust Steam, 4 bar23 MWth
50% - 100%
100%
Process Steam, 4 bar15 MWth
Palm Oil Mill Energy Plant, 60 t/h FFB
24 MWth, 36 t/h
Steam Losses (Avoidable)8 MWth 33 %
Electricity1.4 MWe
* Present Combined Heat & Power
Creating Value from Biomass
Palm Oil Mill Energy Plant, 60 t/h FFB
* Optimised Good Quality CHP – Phase 3Back Pressure
Steam TurbineGenerator
Boiler
Electricity to Mill Bus 1.4 MWe
Grid 5.0 MWe
70 bar
η = 0.80
0%
20%
Biomass Fuel for Export 24 MWth
32,000 tonnes/year EFB Fibre, shell
Mill solid waste fired 20 MW th
Mill biogas fired 6 MWth η = 80%
29 MWth
Process Steam, 2 bar15 MWth
Feed water Heating8 MWth
Exhaust Steam, 2 bar23 MWth
Inventor – Green EnergyIr. Krishna Moorthy,[email protected]
Refinery Complex
Steam saving at fractionation plants
Dry fractionation- 20%
Palm kernel dry fractionation- 66%
Vent economizer- Recovers heat from flash steam from condensate tank
Utilities saving at whole complex
0
20
40
60
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120
140
2013 2014 2015 2016 2017 2018 2019 2020
Stea
m c
on
sum
pti
on
(kg
/ t)
CP
KO
Year
PKDF Plant
0.0
5.0
10.0
15.0
20.0
25.0
30.0
2014 2015 2016 2017 2018 2019 2020
Stea
m C
on
sum
pti
on
(kg
/mt)
RB
DP
O
Year
DF Plant
Heat recovery
Condensate recovery at plants
- CPO washing
- Stearin cake heating
Heat Recovery in Refinery
Year ConfigurationRef 3 (Diesel + LNG) L/t or Sm3/t RBDPO
Reduction (%)
2014Falling film (FF)
5.73 Baseline
2015 5.17 10%
2016
Change to Spiral Heat Exchanger
(SHE)
3.93 31%
2017 3.38 41%
2018 3.65 36%
2019 3.65 36%
2020 SHE + FF 3.03 47%
Heat exchanger, inverter, LED light
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60
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120
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1000
1200
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1600
1800
2000
2017 2018 2019 2020
Co
st S
aved
(U
SD),
th
ou
san
d
Ener
gy S
aved
(Kw
h),
th
ou
san
d
Year
Energy Saved (Kwh) Cost Saved (USD)
Water recycling
4049
67 64
11
10
9812
14
1817
0
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4
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2017 2018 2019 2020
CO
ST S
AV
ED (
USD
) TH
OU
SAN
D
RO
REJ
ECT
& E
FFLU
ENT
TREA
TED
WA
TER
REC
YCLE
D (
M³)
TH
OU
SAN
D
YEAR
RO reject water Effluent treated water Cost saved (USD)
Effluent treatment plant
c) aeration in progress in reactorb) aeration nozzles in reactora) Urea preparation tank
Tanks bypassed
Aeration tank DAF tank
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Green initiatives1. Shorter cycle times reduce electricity
consumption 40% (10,000kWh/ month)2. Saving in chemicals usage contributed to the
reduction of greenhouse gas emissions3. Sludge generated is sent back to the reactors
for digestion by the bacteria.
Close to 85% of the treated water from the ETP is reused as industrial water
Solar sensor
LNG system was commissioned in July 2019 starting at Refinery 2 and Refinery 3.
The more environmental-friendly LNG replaced diesel for Geka boilers and reduced carbon footprint.
LNG has an emission of 0.0758 kg CO₂ eq/MJ which is lower than the emission of diesel rated at 0.0876kg CO₂ eq/MJ.
This project reuses the existing concrete foundation from old Vickers boiler and thus, avoid the use of new pilling and
concrete.
LNG replaces diesel
0.00
0.50
1.00
1.50
2.00
2.50
3.00
0
50
100
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300
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2017 2018 2019 2020
t st
eam
/ t
EFB
, t x
100
0
Year
Steam Generated Steam generated per ton EFB
Biomass boiler
Biomass improvement
No. Descriptions Enco Biomass Boiler Cogeneration
Plant Boiler
New Water
Tube Boiler
1 Boiler feedwater temperature 108 °C 220 °C 260 °C
2 Shell to fibre ratio 25:75 10:90 5:95
3 Extent of fuel combusted 90% 85% 95%
4 Moisture content in fuel 45% 45% 55%
5 Steam generated / t fiber 1.8 1.8 2.6
6 Life of economizer tubes 1 year 5 years > 5 years
7 Superheated steam temperature saturated 480 °C 430 °C
8 Mean time between cleanings 30 days 45 days 60+ days
Olein as bio-lubricant “Bio lubricant" refers to lubricants that biodegrade rapidly and which are non-
toxic for human beings and aquatic habitats. They may be based on plant oils or synthetic esters manufactured
from modified renewable oils
Also as an alternate method to tackle Food safety concern
related with mineral oil - MOSH & MOAH
Dust plants at Kernel Crushing Plant
High Pressure boiler with ESP
0
100
200
300
400Emission (mg/Nm³)
Before After
Wet Scrubber
Reduction in GHG emissions
GHG Reduction over the years (Product)
0
5
10
15
20
25
30
35
RBDPO RBDOL/ STGH
G E
mis
sio
n (
kg C
oշ-
eq/
ton
dry
pro
du
ct)
Year
FY 18/19 FY 19/20 FY 20/21
0
10
20
30
40
50
60
CPKOL/ST RBDPKO/OL/STGH
G E
mis
sio
n (
kg C
oշ-
eq/
ton
dry
pro
du
ct)
Year
FY 18/19 FY 19/20 FY 20/21
National Energy Award.
IOI Bio-Energy emerged Winner in Renewable Energy Co-Generation category of the 2021 NEA
IOI Edible Oils emerged Winner in Category 1 –
Energy Management in Large Buildings category of the 2018 NEA
And Second Runner up at AEA
IOI Edible Oils emerged Winner in IChemE
Palm Oil Industry Award 2018
Publications1. Shyam Lakshmanan & Yen Li Yung (2021). Chloride reduction by water washing of crude palm oil to assist in 3-
monochloropropane-1, 2 diol ester (3-MCPDE) mitigation. Food Additives & Contaminants: Part A.https://doi.org/10.1080/19440049.2020.1842516
2. Mun Cheng Tan, Dominic Chwan Yee Foo & Shyam Lakshmanan (2021). An integrated simulation–optimisationapproach for free fatty acid removal in palm oil deodorisation process. Asia-Pacific Journal of ChemicalEngineering http://doi.org.10.1002/apj.2602
3. Shyam Lakshmanan, Yen Li Yung, Kalaiselvan Palanisamy & How Kee Ling (2020). Lessons learnt from biomass-fueled power plant Journal of Oil Palm, Environment & Health 2020, 11:6-20. http://doi:10.5366/jope.2021.03
4. Shyam Lakshmanan; Yen Li Yung; Boon San Chan & Zhe Haw Chong (2020). Sustainable Practices of an edible oils refining complex JOPEH 2020, 11:42-56. http://doi:10.5366/jope.2020.05
5. Shyam Lakshmanan & Yen Li Yung (2019). Reduction of chlorate and regeneration of activated carbon used for chlorate adsorption Blue-Green Systems 1(1) https://doi.org/10.2166/bgs.2019. 193
6. Shyam Lakshmanan & Yen Li Yung (2019). 3-MCPDe and GE Mitigation Measures in Refined Palm Oil, PIPOC 2019. Poster.
7. Book Title : Sustainable Technologies for the Oil Palm Industry - Latest Advances and Case Studies Editor: Dominic C.Y. Foo, Mustafa Kamal Tun Abdul Aziz and Suzana Yusup
Chapter title : Innovations to a Palm Biomass-Fueled Power Plant
Chapter title: Sustainable Practices of IOI’s Palm Oil and Palm Kernel Processing Complex in Sabah
