biomass waste utilization projects at philrice manuel jose c. regalado, phd supervising science...

Biomass Waste Utilization Projects at

PhilRice

Manuel Jose C. Regalado, PhDSupervising Science Research Specialist

Rice Engineering & Mechanization Division

Philippine Rice Research Institute (PhilRice)

Maligaya, Science City of Muñoz, N.E.

Certified: ISO 9001:2000; ISO 14001:2004; OHSAS 18001:1999

Philippine Rice Research Institute Philippine Rice Research Institute

…as key player in building a self-sufficient and competitive rice economy

• a government-owned and -controlled corporation attached to the Department of Agriculture and created through EO 1061 on 5 Nov. 1985 and strengthened by EO 60 on 7 Nov. 1986

Philippine Rice Research Institute Philippine Rice Research Institute

…to sustain rice self-sufficiency and build a competitive rice economy through research, technology promotion, and policy advocacy

CapacityEnhancement

Sustainability Profitability

Productivity

Integrated Management System (IMS) certified lead agency of the National Agricultural Research and Extension System (NARES) for rice in the Philippines

ISO 9001:2000;ISO 14001:2004;OHSAS 18001:1999

Features• interdisciplinar

y• location-

specific•ecosystem-

based•problem-

specific

Output:Technology &Information

Researchable Areas

Integrated RD&E Approach

Transplanted Irrigated Lowland Rice

Hybrid Rice

Rice-based Farming Systemsfor Fragile Environment

Rice & Rice Based Products

Technology PromotionPolicy Research & Advocacy

Plant B

reedin

g &

Bio

tech

nolog

y

Rice

Chem

. & Fo

od S

cience

Agro

., Soils a

nd Pla

nt Ph

ysiolo

gy

Seed Pro

ductio

n &

Health

Rice

Engr &

Mech

.D

eve

lopm

ent C

om

munica

tion

Socio

-Eco

nom

ics

Tech

. Managem

ent S

ervice

s

Cro

p Pro

tectio

n

Environmental Sustainability & Management Program

Direct Seeded Irrigated Lowland Rice

Institutional Capability & Networking

Composition (57) 2 national centers 6 branch stations 12 regional research

stations 37 cooperating stations

SeedNet: 96 members

International Linkages

PhilRicePhilRice

JICAJICARFRF

IFSIFS IRRI

US Lab

CAMBIA

RGPRGP

ARBNIPM NetILRRCIPSWAR

ScientistScientistCollaboratorsCollaborators

GRCRLRCURRC

Cornell UC DAVISPurdue

ASIAN Lab

ChinaChina

CNRRICNHRRDCJAASGxAASGuAASFAAS

FAO/IRCFAO/IRC

USAID

ADBADB

AustraliaAustralia

ACIAR CSIRO UWA

HAASFAU FAFUSCAUYAUYU

ICRISATICRISAT

PHILRICE – JAPAN BIOMASS CONSORTIUM

MOU June 2002 to May 2005

Dissemination Seminar 2006-07

Collaborating Japanese Companies:

Kansai Corporation Ebara Corporation Takuma Corporation Sanko Corporation ISSI Brain System, ISSI Corp. Funding: NEDO JODC

GASIFICATION, CARBONIZATIONAND COMBINED HEAT & POWER

GENERATION SYSTEM

NEDO–JAPAN BIOMASS CONSORTIUM–PHILRICE COLLABORATIVE PROJECT

Primer

SANKONew Energy and Industrial Technology Development Organization

PHILIPPINE RICE RESEARCH INSTITUTEISO 14001CERTIFIED

• 3.6 M t rice hull (22% of the total paddy production of 16.24 M t in 2007)

• Open burning and uncontrolled combustion is not environment friendly: major source of PCDD/PCDF formed at 200-800 oC

• Wastage of important resources (energy & material inputs for agriculture & industry)

RICE HULL PROBLEMS

• Land, Air, Water Pollution

• Release of harmful chemicals & particles

• Food contamination, exposure to dirt causes skin diseases, respiratory diseases from emission of fumes

HEALTH & ENVIRONMENTAL IMPACTS

• Increasing cost of external farm inputs

• Declining yield due to continuous agricultural mining of nutrients

• Health & environmental impacts of chemical inputs

• Pests & diseases

• Climate Change: GHG emissions, El Niño, La Niña

PROBLEMS in the PRESENT RICE-BASED PRODUCTION SYSTEM

• Return (by-products) what has been taken from the soil

• Maximize the utilization of available sources of nutrients

• Maximize air N fixation

• Farmers to make their own organic fertilizer

GUIDING PRINCIPLES

10-20 kW Gasification, Carbonization & Combined Heat & Power Gen Setup

• Develop modular small scale cleaner production resource recovery systems• Produce gas, heat, mechanical and electrical power• Produce by products such CRH and liquid materials for soil conditioning, organic fertilizer, and natural pesticide among others.

Smoke vinegar Carbonized Rice Hull (CRH)

• Testing and Evaluation (Endurance & Durability)

• Market Research & Commercialization

• Dissemination seminars

COLLABORATIVE ACTIVITIES

Gasification plant

Gasifier, scrubber and gas holder

Ash out

Air in

Gas out

Motor

Hopper

Ash moving blade

Level sensor

Motor

Fuel conveyer

Rotary stirrer

ThermocouplesAsh conveyer

Schematic of the gasifier

The Gasification System

Gas engine and electric generator

Rice husk gas lightening at night

Producer Gas Composition

  CO (%)

CO2 (%)

H2 (%)

O2 (%)

Ave 21.07 7.62 0.72 9.38

Max 36 31 1.56 16.5

Min 0.8 0 0.08 3.0

Some Visitors

Hour of operation 　 　 8 hTotal input of rice husk 　 　 431 kgFeed rate 　 　 53.9 kg/hTotal discharge of CRH 　 　 92.6 kgDischarge rate of CRH 　 　 11.6 kg/hCRH conversion ratio 　 　 21.5 %Temperature of combustion zone 　 600-750 ℃Gasification efficiency 　 　 46 %Power generation 　 　 13 kWGeneration efficiency 　 　 9.2 %

Performance Indices of the Gasification System

Upcoming Technology

Rice Hull Gasifier –Engine –Pump System (2006-08)

• 6.5 kg RH load/batch; 1.5h operation• 6 min start-up & firing time• 3-in pump; 6.5 hp engine; 6-9 L/s

CARBONIZED RICE HUSK& the

AUTOMATED CARBONIZATION SYSTEMin the Philippine Rice Industry

CARBONIZED RICE HUSK& the

AUTOMATED CARBONIZATION SYSTEMin the Philippine Rice Industry

Problems & Issues

Rice husk (hull) burning: Release of CO2, air pollutants Dumping: CH4 emissionHealth & safety issues

Rice Husk Energy Potential

Process energy required:Paddy milling and drying: 30-60 kWh/tonne paddy

1 tonne ofPaddy

650-700 kgWhite rice

Waste:220 kg Husks ~ 90-125 kWh

Energy from 1 ton rice hull = Energy from 23 11-kg tanks LPG

(3000 kCal/ kg)

Source: BAS, NFA

Total No.: 9,938 Mills

NORTHERN MINDANAO

SOUTHERN TAGALOG

2007 palay production: 16.2 M mt

rice husk: 3.6 M mt

CARBONIZED RICE HULL (CRH)

• Porous, bulk density of 0.1

• Prolongs the duration of sunlight, increasing soil and water temperature

• Contains P,K,Ca,Mg, microelements

• Sterilized: Pathogen free

• Absorbs 5-6 times by weight

• Habitat of beneficial microorganisms

• Substrate for bioorganic fertilizer

How to use CRH

AgriculturalUses

IndustrialUses

Soil ReformerOr Fertilizer

Soils For Seed-BedsAnd Flower Pots

Replenishing Silica

Softening Soil

High Water Retention

Reforming Acid Soil

Protecting AgainstDisease

Paddy

Vegetables, Fruits, Flowers

Deodorizer / Purifier

Humidity Regulator

Heat Insulation Of Iron

CRH

Application of CRH in Agriculture in the Philippines

• Microbial Inoculant

1:1 (CRH:RB) 3% EM, 3% Molasses

• Organic Fertilizer

4:4:1:1 (CRH:CM:RB:Soil)

3% EM, 3% Molasses

• Soil Amendment

100 bags (10 kg) per cm plowed soil

General uses of CRH

• Soil conditioner

Improves physical, chemical and biological properties of soil

Healthy crops• Substrates for microbial inoculant

- Compost starter

- Soil inoculant

- Animal bedding treatment

- Garbage treatment

- Decontamination of toxicants• Feed additives

- Increase feed conversion efficiency

- Regulate and stop scouring of piglets

- Cure of diarrhea

EM formulations• EM-1 is the original

formulation. General purpose formula for soil and plant inoculant, compost starter, deodorizer, waste water treatment, drinking additives and for making other EM formulations such as EMAS, EMI, FPE, EFS.

EM formulations• EM microbial base inoculant

(EMBI) is fermented organic materials such as rice bran, cocodust, sawdust, CRH or other organic materials. Use as soil inoculant, compost starter, nutrient source and feed supplement. 1:1 ratio of organic materials and CRH + 5% EM 1 and 5% molasses fermented for 5-7 days.

Applications

• Soil inoculant. EM 1 or EME is applied into the soil

• Plant inoculant. EM is sprayed or sprinkled to the plants.

• Seed inoculant. Soak seed in 1:1000 dilution rate. The length of time depends on seed size. Small seeds is soak for 2-4 hrs, medium seeds, 8-12 hrs and larger seeds or with hard shells for 1-2 days.

• Compost starter. EMBI, EM 1, EMAS enhance decomposition

• Deodorizer/Sterilizer. Remove foul odor, reduce flies. Decontaminates water

Other applications of EM

• Crop Maintenance• Animal health care • Fish pond

maintenance• Solid and waste water

treatment• Homecare• Industrial

Bioremediation of toxicants in biomass wastes

• EM microbial inoculant reduced the amount of heavy metals (lead, cadmium and mercury) spiked in biomass wastes during two-week period of fermentation.

Bioremediation of Heavy Metals Using EM

Methods• Kitchen garbage spiked with 10

ppm Lead and 2 ppm Cadmium• MBI was inoculated at 100g/kg

waste• Materials fermented for 7 days• Extraction and analysis was

done before treatment and at 7, 20 and 30 days after treatment

Results– 20-70% reduction

of Lead concentration

– 20-90% reduction of Cadmium concentration

Preventing Vegetables And Fruits From Rotting.

Industrial Uses of C.R.HDeodorizer / Purifier

Dirty water / Air Bio-Tan Clean water / Air

Pass Through

Blast Furnace

Ladle

C.R.H.

ConverterOr

Electric Furnace

Heat Retention

Heat Insulation of Iron Works

Humidity Regulator

Oil Adsorbing by C.R.H

Pour oil in water

Add Bio-TanOil & Bio-Tan on water

Remove Bio-TanOil doesn’t retain

Automated Carbonization System

• Produces good quality CRH, 21 tpd

• No black smoke

• Auxiliary fuel is not needed

• Long durability

• No trouble and easy replacement of parts

CRH GENERATIONCRH GENERATION

Old-fashion way:Old-fashion way:

Automated Carbonization System

Rice Mill

HuskStorage

CRHStorage

Carbonizer

CRHExtinguisher

Waste HeatBoiler

Chimney

TurbineGenerator

ElectricPower

ACS ESTABLISHMENTACS ESTABLISHMENT

• MOA signing 2004: 3 ACS units

• Design modification

• Site development

• Fabrication of local & imported parts

• Set-up and installation

• Commissioning

• Repair and maintenance

OLIVER ENTERPRISES