: case of upm, malaysia and kyutech,...

International Joint Collaboration

: case of UPM, Malaysia and KYUTECH, Japan

WAKISAKA Minato

Graduate School of Life Science and

Systems Engineering,

Kyushu Institute of Technology(KYUTECH),

2-4 Hibikino, Wakamatsu-ku, Kitakyushu

808-0196, Japan

Email: [email protected]

Presentation material for MAFF&R1

28 FEB 2011

ＦＭ

ＷＥ

Ｅ

ood

aterial

ater

nergy

cology

Biomass-Based Plastics

Kitchen

Garbage

Bio-Fuel

PLAPBSCellulose

Organate

International Joint R&D on

Oil Palm Biomass Zero Emission

GHG

reduction

Marine BiomassMarine Biomass

SeaweedSeaweed

EFB

Biomass-Based Functional Materials

Dye-sensitized Solar Cell Porous Film

Contact Address:

[email protected]

Associate Prof. Minato WAKISAKA

Department of Biological Functions and Engineering

Graduate School of Life Science and Systems Engineering

Kyushu Institute of Technology

2-4, Hibikino, Wakamatsu-ku, Kitakyushu 808-0196, Japan

Contents

1. Introduction

2. Mottainai ! -case1

Bio-ethanol from Food Waste in Kitakyushu Eco-town


Methane capture from POME in Malaysia

4. Systems Design for Biomass Town

City of Kitakyushu

Pioneer City of Heavy Industry & Eco-Activities

Kitakyushu Eco-town

The government-owned Yawata Steel Works

The government-owed

Yawata Steel Workswas established

in Kitakyushu in 1901.

It was

the FIRST HEAVY INDUSTRY

company in Japan,

and Kitakyushu had been

the most important industrial district.

Kitakyushu is now

the most advanced city

in Japanwith regard to

POLLUTION CONTROL and

RECYCLING TECHNOLOGY.

‘Use all waste as material for other industries,

reduce waste as much as possible

(zero emission)'

Background-Challenges in Kitakyushu Eco-town

Bioconversion of Food

Waste to Bio-fuel,

Bioplastics

Pilot-scale Actual Proof

in Kitakyushu Eco-town

Starch Material

⇒Food vs Fuel

(1st Generation)Biomass Derived Plastics

Eco-Town

Collaborative

R&D Center

for the

Environment

and Recycling

Food

Waste

Bio Ethanol

Poly

Lactic

Acid

Poly

Butylene

Succinate

Cellulose

Organate

Contents

1. Introduction






Panoramic view of the food waste-to-ethanol facilities

Edo period (1603-1868 CE)

MOTTAINAIMOTTAINAIAre you sure you are not doing anything mottainai?

Mottainai is the thoughtful Japanese word with love and compassion to think of the gift from the nature or someone who made the product.

(4R[Reduce, Reuse, Recycle+Respect])The word closest to Mottainai in English is "What a waste!", "Do not waste!" or the situation a thing is being wasted or being used without good care and consideration.This word was introduced as Eco-friendly word by Hon.Prof.Maathai at UN.

"Mottainai Grandma" is the picture book which was published in Japan 2004.(Mottainai Baasan / Japanese title.)

Saccharification FermentationEvapora

tion EsterificationDistillati

on HydrolysisS/L

separation

Food Waste

Residue

→→→→Fertilizer

LA

Lactide

Polymerization

PLA

Syrup

Fermentation

Distillation

Ethanol

ECO-TOWN CENTER in KIT

5

ポリ乳酸の商品化例

トヨタスペアタイヤカバー

イオン卵パック他包装材

西川リビング／東レエコデェア

ハスキー飲料ボトルＢＩＯＴＡ

ユニチカ耐熱発泡成形品

富士通ノートパソコン「FMV-BIBLO NB80K」

ＬＳＩ包装用

エンボステープ

ソニーウォークマン NEC

ＦＯＭＡ 701i ECO

Panasonic卓上ホルダー

Panasonic乾電池パッケージ

Material/Energy conversion from Food Waste

12

②High-efficiency ethanol fermentation

Flocculating yeast

③Supply of low-pressure steam and inexpensive

electricity by the adjacent melting furnace

Gasification and melting furnace

System for Converting Food Waste into Energy

EthanolPretreatment

Measures for solving problems in the system of converting food waste into

energy

Saccharification Fermentation Purification

Characteristics of the system

④It is possible to treat the residues and wastewater generated

in the process as well as collect heat at the adjacent

melting furnace.

Residues &

Wastewater

①Focusing attention on the sugar content of food waste

Enzyme

Heat (Steam) Electricity and other utilities

Food waste

13

Outline of the Experiment System

•Foreign

substances allowed

•Using ID tags

12t/d

2t/dForeign solids

・・・・Two-chambered

separate collection

vehicles

10t/d15t/d

Solids residues

5t/d・・・・Treatment of

residues at the

incinerator

・・・・Utilizing steam emitted

by the incinerator

Conversion into energy & Utilization

Converting into energy & Utilization

Pretreatment Saccharification

Separationof solids

and liquid

Concentration

Fermentation

Distillation & Membrane separation

・・・・Nutritious

supplement

unnecessary

・・・・High-efficiency

fermentation by

flocculating yeast

Dehydrated ethanol

400L/d

・・・・Use of E3 gasoline

•Official vehicles of the City of

Kitakyushu

•Vehicles for business use owned by

companies in the city

Collection & Transport

Carrying in

End use of energyCarrying out

Raw garbage

5 t/d

Water

Food Waste Composition

Fat contribute to high

calorific value

Sugar 10.1%

（Glucose＋Fructose）

HHV 6,613 kJ/kg

LHV 4,415 kJ/kg

SugarSugarSugarSugar

10.1%10.1%10.1%10.1%OthersOthersOthersOthers

0.9%0.9%0.9%0.9%MineralMineralMineralMineral

2.4%2.4%2.4%2.4%

FiberFiberFiberFiber

0.9%0.9%0.9%0.9%

FatFatFatFat

9.8%9.8%9.8%9.8%

WaterWaterWaterWater

71.1%71.1%71.1%71.1%

ProteinProteinProteinProtein

4.8%4.8%4.8%4.8%

→Potential EtOH Productivity

66L/t-wet

221L/t-dry

Fermentation Profile（Pilot Scale）

発酵槽発酵槽発酵槽発酵槽

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 24 48 72 96 120 144 168 192 216 240 264 288 312 336 360 384 408 432 456 480 504 528 552 576

時間 [h]時間 [h]時間 [h]時間 [h]

濃度

[g/L]

濃度

[g/L]

濃度

[g/L]

濃度

[g/L]

-2.00E+07

6.00E+07

1.40E+08

2.20E+08

3.00E+08

3.80E+08

4.60E+08

5.40E+08

6.20E+08

Glucose Ethanol Initial Glucose Yeast cells

Stable operation of continuous fermentation for 24 days in

900L reactor

Inlet glucose conc 100g/L, Outlet EtOH conc 60g/L

Most of the sugar (97-98%) converted to EtOH

Viability of 3×10８ cell/ml maintained

Sample

Left: Saccharification Liquor, Fermentation Broth, EtOH, E3 Gasoline: Right

Material Balance of Food Waste to EtOH

Food Waste to

EtOH Process

Food

Waste

10t/day

Ethanol

450L/day

Oil

Recovery

550kg/day

Residue

5.2t/day

(Water4.1t)

Evaluation of recovered oil

反応引火点

℃

動粘度

（50℃）

Ｃｓｔ

流動点

℃

残留

炭素分

Ｗｔ％

水分

Vol％

灰分

Ｗｔ％

硫黄分

Ｗｔ％

発熱量

kJ/ｋｇ

Ａ重油１号中性 60以上

20以下

5以下

4以下

0.3以下

0.05以下

0.5以下

39,100

Ｃ重油１号中性 70以上

250以下

― ― 0.5以下

0.1以下

3.5以下

41,700

回収油 ― 72.5 26.5 2.5 0.5 0.2未満

0.01 0.01 36,469

Oil recovered from EtOH production mainly due to fat of

food waste.

Substitutive for fuel oil because of lower sulfur content

and viscosity,although lower calorie value.

Residual Component

ＣＣＣＣ/ＮＮＮＮ

Water％％％％

Organic

％％％％

Mineral

％％％％ＣＣＣＣ

％％％％-ｄｒｙｄｒｙｄｒｙｄｒｙ

ＨＨＨＨ


ＮＮＮＮ


ＯＯＯＯ


Food Waste ７１．２７１．２７１．２７１．２２７．４２７．４２７．４２７．４２．４２．４２．４２．４４９．３４９．３４９．３４９．３７．３７．３７．３７．３２．４２．４２．４２．４３３．９３３．９３３．９３３．９２０２０２０２０

Residue ７６．３７６．３７６．３７６．３２１．９２１．９２１．９２１．９１．８１．８１．８１．８４４．６４４．６４４．６４４．６６．７６．７６．７６．７３．７３．７３．７３．７３８．１３８．１３８．１３８．１１２１２１２１２

Oil ００００１００１００１００１００００００７６．６７６．６７６．６７６．６１１．７１１．７１１．７１１．７０．００．００．００．０１１．７１１．７１１．７１１．７－－－－

C/N ratio of residue decreased (Because carbon

component converted to Ethanol and protein remained)

Energy Balance

Energy Conversion（Lower Heating Value Basis）

Target EtOH EtOH+Oil

① Final Energy /(Biomass＋External Enery) 15％< 23％ 65％

LHV

CarbohydrateEtOH

Latent

Heat

Fat

Oil

Protein

Residue

FiberOthers

0%

25%

50%

75%

100%

1 2 3

Energy Balance

Residue：：：：ErErErEr

Power

GenerationFood Waste

Co

mb

ustio

n

He

at

Re

cov

ery

BiomassBiomassBiomassBiomass：：：：EiEiEiEi

External EnergyExternal EnergyExternal EnergyExternal Energy：：：：ExExExEx

EtOHEtOHEtOHEtOH：：：：EoEoEoEo

Loss

EtO

H

Pro

du

ction

Bio-Diesel from Waste Oil/Sludge

Dr. Ajay Arora from Indian Oil Corporation

research attachment for 3month (Nov09-Jan10)

Conversion of oil obtained from saccharified kitchen waste to Biodiesel

•Dark brown colored viscous with sediments

•Acidic in nature

•Biodiesel preparationRemove the sediments by centrifugation, moisture from oil under reduced pressure

Two step conversion

-acid catalysis using hexane and methanol as solvent

-base catalysis using methanol as solvent

-reaction progress monitored by TLC and GPC

1HNMR of biodiesel

AVG. Molecular formula C18 H34O2

Ratio of polyunsaturated to mono

saturated for our sample= 0.47:1

Ester of palmitic acid = 20.2 %

Ester of stearic acid = 5.5%

Ester of oleic acid = 45.2%

Ester of linoleic acid = 19.8%

Ester of linolenic acid = 3.75%

GC analysis of Biodiesel

Contents

1. Introduction




Methane capture from POME for CDM in Malaysia


Methane Fermentation is good tool for converting waste to

wealth,

applicable to wide variety of biomass

Background-International Collaborative R&D

Palm Biomass Initiative

Methane Capture from POME treatment

Bioconversion of EFB

△Pretreatment

Lignocellulosics

⇒GHG Emission via Land Use Change

(2nd Generation)

Biogas and Biomass

Utilization in Malaysian

Palm Oil Industry

CDM project

Palm Biomass

Empty Fruit Bunch

Malaysian Palm Oil Industry

Palm Oil Mill Effluent45 million tonnes

Fresh Fruit Bunch67.5 million tonnes

Oil ExtractionCrude Palm Oil

13.9 million tonnesPalm Kernel Oil

1.6 million tonnes

Empty Fruit Bunches 14 million tonnes

Fiber 0.8 million tonnes

Shell0.5 million tonnes

Renewable Resources

Untapped Energy

• Processed fresh fruit bunches – 67.5 million tonnes

• Empty fruit bunches – 13.5 million tonnes (22% of FFB)

– Fertilizer (bunch ash) and soil mulching

• Mesocarp fiber – 0.8 million tonnes

– Boiler fuel for steam/power generation

• Palm kernel shell – 0.5 million tonnes

– Boiler fuel for steam/power generation

Palm Oil Industry – Biomass

• Palm oil mill effluent (POME) – 45 million tonnes/year (2.5-3.0 x CPO)

– POME treatment facility – anaerobic, facultative and aerobic

– Open tanks and lagoons

– Treatment for safe discharge, BOD 25,000ppm down to 100ppm

– Extensive and efficient system (> 70% of total mill area)

– Biogas emission - 28m3 /m3 POME, with 65% methane content

– Untapped renewable energy

Palm Oil Industry - POME

Palm Biomass Utilization under CDM Business

Mitigation Methods CDM Projects

PowerGeneration

BiomassIndustry

EnergyNew

Bioproducts

BIOMASSGENERATION

WASTEDISPOSAL

Greenhouse GasesEmission

Global WarmingClimate Changes

EnvironmentalPollution

Health Hazard

Research Background

Methane from palm oil industry

Anaerobic Ponds Open Digesters

Actual MethaneEmission

Establishedmethodologies

POME Data

Mitigation Method: CDM Project

Methane Fermentation Plant

CDM

Developed Country Joint Project Developing Country

Reducing GHGBoundary Space

Time < 2012

Base Line Measurable

Joint Project No

YesGHG

reduction

Baseline study: Site descriptions

• Serting Hilir Palm Oil Mill

• Anaerobic Treatment:

– 3600 m3 open digesters (6 tanks)

– HRT 20 days

• Serting Palm Oil Mill

• Anaerobic Treatment:

– 7500 m3 anaerobic ponds (4 ponds)

– HRT 40 days

Baseline studies: Findings

• Correlation between CH4

emission & COD removed

– Open tank – 0.109kg CH4/kg

COD removed

– Anaerobic pond – 0.238kg CH

4/kg COD removed

• COD removal efficiencies of anaerobic process

– Open tank – 80.7%

– Anaerobic pond – 97.8%

Open Digesting Tank

0

400

800

1200

1600

5000 5500 6000 6500 7000

CH4 (

kg

/d

ay

)

Anaerobic pond

0

500

1000

1500

2000

2500

0 2000 4000 6000 8000

Total COD Removed (kg/day)

CH4 (

kg

/d

ay

)

Baseline studies: Conclusions

1. Long term field measurement is important in establishing actual CH4 baseline emission

2. CH4 emission was strongly influenced by:

• Oil palm seasonal cropping

• Palm oil mill activities

3. Average CH4 content in biogas was lower (36% - 54%) than reported earlier in lab studies (65%)

4. Total CH4 emission were:

• 849-864 tonnes/year (open digester system)

• 1061-1125 tonnes/year (anaerobic pond system)

5. Established methane emission methodologies

Methane pilot plant

RAW POME

Q (m3/d) 50

pH 4.2

COD (ppm) 50000

BOD (ppm) 25000

SS (mg/L) 18000

OLR (kg/m3/d) 5.0

TANK DESIGN CAPACITY

Volume (m3) 500

HRT (days) 10

DISCHARGED EFFLUENT

Q (m3/d) 50

COD (ppm) ?

BOD (ppm) ?

GAS PRODUCTION

Q (m3/d) ?

CH4 content % 65%

Gas Potential (kg /kg COD) ?

Designed by Sumitomo Heavy Industries Pty. Ltd. Constructed by FELDA Palm Industries Sdn. Bhd.

Pilot plant: 1st Phase Construction

Commenced in July 2003, commissioned in April 2004

Pilot plant: 2nd Phase Construction

Commenced in February 2005, commissioned in July 2005

Future Research: Optimization & Gas Utilization

BIOREACTORMethane fermentation

HOLDING TANKContinuous feeding

GAS STORAGEMethane storage

GAS SCRUBBERBiogas polishing

GAS UTILIZATIONSETTLING TANK

Sludge separation

Sludge recycle

JOINT JOINT

RESEARCH & DEVELOPMENTRESEARCH & DEVELOPMENT

2004 2004 -- 20072007

UNIVERSITY PUTRA MALAYSIAUNIVERSITY PUTRA MALAYSIA

FELDA PALM INDUSTRIES SDN. BHD.FELDA PALM INDUSTRIES SDN. BHD.

KYUSHU INSTITUTE OF TECHNOLOGYKYUSHU INSTITUTE OF TECHNOLOGY

UTILIZATION OF UTILIZATION OF

BIOGAS AND BIOMASS BIOGAS AND BIOMASS FOR NEW BIOPRODUCTSFOR NEW BIOPRODUCTS

Palm oil mill effluent (POME) is the largest by-product generated from the palm oil mill. Despite this, it has no commercial value, currently being biologically treated before safe discharge. It was found that approximately 1000 tonnes of CH4 is emitted annually from the treatment system in FELDA Serting Hilir Mill based on our baseline emission study conducted in 2003 . Thus, there is a potential for a renewable energy project from POME treatment.

Our experience has shown that the methane fermentation process of POME can be further improved. Designed by Sumitomo Heavy Industries Ltd. (Japan) and constructed by FELDA Palm industries Sdn. Bhd., an improved design of 500 ton CH4 fermentation tank was built as a biogas pilot plant. The objectives of the pilot plant are to increase the efficiency of POME treatment and CH4

fermentation for use as energy, possibly electricity generation under CDM.

The pilot plant was fully operational in July 2005 after being commissioned in April 2004. Improvement in POME treatment and methane fermentation were achieved compared to conventional system. The specifications andperformance of the pilot plant are as indicated below.

14 monthsTotal time of construction

Automated pH control @ 7

37-42oCOperating Temperature

AvailableGas & sludge recycle systems

8 g/LSolid dischargeFloating type, 20 m3Gas Storage

0.2kg-CH4/kg-COD

Biogas production InstalledGas scrubber

55 % (>80%, scrubbed)

Methane content Continuous & suspended

Bioreactor system

90 %Hydrogen sulphide removal efficiency

10 daysHydraulic retention time

95 %COD removal efficiency

500 m3Bioreactor capacity

PerformanceSpecifications

METHANE RECOVERY TEST PLANT

Mitigation measures: Methane utilization

1. Electric power generation using gas turbine

• Internal office use and external lighting

� reduce diesel usage during mill’s non-operating hours

• Aeration of treated effluent to remove remaining BOD

� increase POME treatment efficiency

� reduce large land requirement

2. Methane combustion for steam/electricity generation

• Reduce usage of shell (additional revenue)

• Reduce black smoke emission from shell combustion

3. Production of natural gas for vehicle or household use

Integrated Biogas Process

Fuel Cell

Catalyst

→→→→Chemicals

Compressed

Gas Vehicle

Bio-char

↓↓↓↓

Water Recycle

• Collaborative Partners

– AIST, FELDA, Mie Univ

• Saccharification of cellulose to produce sugars

• Sugar & lignin raw materials:

– Lactic acid fermentation, for poly-lactate (bioplastic)

– Lignophenol production (biopaint)

– Acetone-Butanol-Ethanol (ABE) fermentation (solvents)

• Screening for potential cellulase producing microbes

• R&D on optimization and separation processes for future mass production

Spin-off Projects – Utilization of EFB

Zero Emission with Sustainable Development of Palm Oil Industry under CDM Projects

Empty Fruit Bunch > 14 million t/yr

Palm Oil Mill Effluent> 45 million t/yr

Concentration of biomass “business as usual”

Sugar

Saccharification of cellulose

Electricity

Organic acids

Bioplastics (PHA)500 m3 Biogas Pilot Plant

Ethanol

PLA

LigninLignophenol

Sustainable Management of Agro-Eco-Socio System

CDM provides profitable area for novel business to which biomass energy can be supplied from palm oil industry with a very good price

Novel Business

Novel Business Using Biomass from Palm Oil Industry in Malaysia

CDM provides methane fermentation system changing lagoon into a profitable area.1. CDM can reduce GHG by sealing the lagoons.2. Local pollution can be prevented (odd smell from lagoons stopped)3. Local employment can be encouraged by inviting novel business.

CDM provides electricity using biogas from methane fermentation system for the novel business with a competitive price.



Novel Business

Novel Business Using Biomass from Palm Oil Industry in Malaysia

CDM provides methane fermentation system changing lagoon into a profitable area.1. CDM can reduce GHG by sealing the lagoons.2. Local pollution can be prevented (odd smell from lagoons stopped)3. Local employment can be encouraged by inviting novel business.

CDM provides electricity using biogas from methane fermentation system for the novel business with a competitive price.

Creation and Development of Palm Biomass InitiativeCreation and Development of Palm Biomass Initiative

JSPS Asian CORE Program (2005-2009)

CORE INSTITUTION: Kyushu Institute of Technology (Japan)

University Putra Malaysia (Malaysia)

CDM Simulation Project

JOINT RESEARCH COLLABORATION BETWEEN MALAYSIA-JAPAN� Government institutions� University Putra Malaysia & Kyushu Institute

of Technology� Private sectors� FELDA Palm Industries & Sumitomo Heavy

Industries

BENEFITS ACHIEVED� CDM simulation

� Private sectors collaboration

� Government bodies cooperation

� Transfer of technology

� Mitigation of methane emission

� Improvement of current system

� Reliability of local engineering consortium

� Total cost of construction ≈≈≈≈ RM800,000

� Potential generation of renewable energyCommercialization of CDM

Retrofitting current digester tank

Air/Water

Environmental Assesment

Forest

（Peat Swamp）

Oil Palm

Plantation

Water

Quality？

GHG？

Water

Environmental Impact Assesment

Feeding Plantation

EFB rich in K

Essential for

Sustainability

Promising Business

Potential!

Compost

(POME+EFB)

Soil

TECHNOLOGYEC OLOGY

Contents

1. Introduction

2. Mottainai -case1!


3. Mottainai -case2!



Technology Showcases,

But few community commitment

How to trigger/appeal to community?

Be a Social Changemaker/Entreprenur!

Systems Design

Way of thinking catching whole picture with new

and deep insight leading innovation

Zero Emission

Bio mimicry

Slow Food

Branding Strategy

Innovation: Agro-Bio-Complex

Primary Industry：

Agriculture,Forestry,Fishery

×

Secondary Industry：Manufacturing

×

Tertiary Industry：IT, Service

Additional Value

Job Opportunity

Biomass Town

3 in 1

1.Technology Showcase (Education)

2.Industrial Training

3.CommunityBusiness

Millionaire by collecting leafhttp://www.irodori.co.jp/

Find hidden treasure in your town!

One village, One Product

-> Local Delight

Ex) SAWARI @FELDA

Natural Resources (beautiful scenery),

Traditional custom, People

How to create your future?

Sustainable

Society

Thank you for your attention!

Wish you have

Safe biomass town visit

&

Good imagination to create

World capital of Biomass!

: case of upm, malaysia and kyutech,...

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