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Department of Alternative Energy Design of crude palm oil extraction system with complete Development and Efficiency cycle of bio-diesel productions and electrical generation project.

Executive Summary

Silapakorn University 1

Content

Pages 1. Principle and background 1

2. Objectives 1 3. Scope of work and methodology 1 3.1 Scope of work 1 3.2 Methodology 3 4. Results 4 4.1 Literature reviews 4 4.2 Project area survey 4 4.3 Cover building design 5 4.4 Design of wastewater treatment system 10 4.5 Design of crude palm oil extraction system 11 4.6 Design of biomass electrical generation 13 4.7 Biomass fuel cutting machine 15 4.8 Design of transmission line and electrical connections 15 4.9 Summary of crude palm oil extraction system with complete cycle of bio-diesel

productions and electrical generation 5. Biding documentary 18


Executive Summary


Executive Summary

1. Principle and background

Socials component has recently been affected by the world economics crisis. Thailand also highly tends to be in trouble, leading to the stability problem of our domestic energy. For this reason, Department of Alternative Energy Development and Efficiency (DEDE), Ministry of Energy, has provided the 15-years plan using biomass as an alternative energy in order to decrease the fossil consumption by controlling the self production and manipulating the most effective, domestic, biomass consumption. Not only maintaining the energy stabilization, the agricultural products can be also well supported. In additions, the bio-diesel industry promotion has to be seriously managed. The oil palm farming, therefore, has been increased by the encouragement of government and private individual organizations. Consequently, some agriculturists develop several farming zones, and continuously plant the oil palm in assorted areas. If there was no expansion of development and promotion of oil palm applications simultaneously, the new faced agriculturist would be affected by the inefficiently utilized products. The damage results to the agriculturists would not eventually be avoided.

Hereafter, DEDE aims to develop a practical project of crude palm oil extraction for a complete cycle of bio-diesel productions and electrical generation, and supporting the agriculturists who have potentially advanced new palm farming areas, e.g., central and north-east region, far away from the former resources. Regarding the post harvest palm product, an agricultural process must be done urgently, unless the product quality and quantity are all decreased.

2. Objectives 1) To investigate and design the cover building for the crude palm oil extraction

system, the wastewater treatment system due to the bio-diesel process, and electricity generating system.


Executive Summary


2) To investigate and design the crude palm oil extraction machine, the wastewater treatment system due to the bio-diesel process, and electrical generation system using biomass.

3. Scope of work and methodology 3.1 Scope of work

1) Properties of empty palm fruit bunch, bio-gasification production technology using empty palm bunch or other biomass as a fuel for electrical generation, and wastewater treatment system due to the bio-diesel process, both domestic and international, have to be investigated and reviewed.

2) The practical project area has to be surveyed in the area of DEDE at the 4th academic service center (Nong Khai Province) Amphur Muang, Nong Khai, or other area that is appropriated

3) The system cover building has to be achieved suitably with using area of no less than 120 m2. One or more buildings can be constructed depends on the project area in order to obtain the most optimum layout for all the equipments set up in the cover building, i.e., crude palm oil extraction machine, electrical generating system using biomass (capacity no less than of 100 kW), biomass fuel cutting machine (empty palm fruit bunch cutting machine), and etc. Storage areas for the palm fruit bunch and empty palm fruit bunch have to be accomplished for the oil extraction and fuel for electrical generation, respectively.

4) The wastewater treatment system is designed to clean the wastewater from the crude palm oil extraction. BOD of the wastewater at final procedure must not exceed 200mg/liter. The treatment system has to be appropriately placed outside of the system building.

5) The crude oil extraction system is designed by non-seed palm process and low investment cost with production capacity no less than 1.5 ton-palm-bunch/hour, or corresponding to the local bio-diesel production system with 2,000 liter/day.

6) The specification of electrical generation system by biomass gasification, using empty palm bunch with no less than 100 kW, is as follows.

6.1) Biomass gasification, using empty palm bunch as fuel with optimal capacity, can be used with an electrical generating system no less than 100 kW. The


Executive Summary


main components of the system are biomass reactor, gas cooling system, gas cleaning system, fuel gas blower, fuel gas piping system, and etc.

6.2) Main equipments for the electrical generating system, no less than 100 kW, are an optimal water-cooled internal combustion engine using biomass as a single fuel, electrical generator with capacity of no less than 100 kW., and other necessaries.

7) The specification of biomass cutting machine (empty palm fruit bunch cutting machine) has been optimally established. The empty palm bunch must be cut as small as the electrical generating system’s fuel.

8) Transmission line and electrical connections have been designed for the use in the project and connecting to the main power line of Provincial Electricity Authority (PEA).

9) 50 copies of project’s bid document have been submitted to the DEDE. The details are specifications, quotation form, median price and the related sources. The drawing plan can be immediately employed for the construction. Other plans require the clearest details for the bid. 3.2 Methodology

The consultants team has a distinctly approach for the development and design of crude palm oil extraction, since the product of the extraction can be further used as raw material in bio-diesel production/wastedwater treatment systems. Biomass production, which is used to produced electricity for all the equipments and machines and sell the excess electricity back to the PEA, have been done effectively and optimally to the local community. The 6 principal steps for this project are illustrated in Figure 1.


Executive Summary


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Figure 1. The project procedure


Executive Summary


4. Results 4.1 Literature reviews

The concerning data and information have been reviewed as follows. 1) Palm bunch properties: general information of oil palm, farming area and

products from the oil palm, biomass potential evaluation of the oil palm, chemical component analysis of empty palm bunch, and optimal study on using biomass from oil palm for electricity generation.

2) Crude palm oil extraction technology: steamed and non-steamed extractions. 3) Biomass fuel shortening system: empty palm bunch shortening system and

samples of empty palm bunch pulverized technology. 4) Biomass production system: biomass fuel gas production pattern using

chemical heating process, related factors to the fuel gas production, biomass stove model, electrical generation using biomass, international and domestic technology developments, the comparison of electrical generating system using biomass, and the comparison of economic optimization among variety types of fuel gas productions.

5) Wastewater treatment: water treatment before releasing into public water, wastewater reviews, types of wastewater treatment, wastewater technology, and the quality standard of wastewater.

4.2 Project area survey The area of academic service center, located in oil palm farming area, northeast

of Thailand, had been surveyed, i.e., the 4th academic service center in Nong Khai (Figure 2), and the 6th academic service center in Ubon Ratchathani (Figure 3). The surveyed topics are as follows.

Background and responsibilities

Human resource structure

Oil palm farming information in the responsible area of academic service center

Survey of readiness and the optimum of the academic service center

Maps and transportation


Executive Summary


Figure 2. The 4th academic service center, Nong Khai

Figure 3. The 6th academic service center, Ubon Ratchathani

The optimal dimensions of the academic service center had been compared, including the center intra-transportation, transportation between the center and selling-farming oil palm places, the drainage of the factories, environment effects, raw material resources, staff potential, and power transmission line. It was found that the 6th academic service center, Ubon Ratchathani, was the most optimal area for constructing the prototype factory of crude palm oil extraction with. 4.3 Cover building design Consultance had designed the cover building for the crude palm oil extraction with a complete cycle of bio-diesel productions and electrical generation. This building was fit well to the area of the 6th academic service center, Ubon Ratchathani. The area and soil standard test had been exhaustively surveyed for the building design.


Executive Summary


The prototype factory of crude palm oil extraction with a complete cycle of bio-diesel productions and electrical generation had been designed, including the infrastructure, architects, building maintenance service design, and electronic truck scale system. The construction budget is 13,665,000.00 baht as the detail follows.

1) Seven 870-m2 working zones are in the cover building (including the indoor walkway)

2) Five 450-m2 working zones are out of the cover building. 3) Palm storage zone was at the entrance street, the production process was

planned from outside into the area, and the receiving oil terminal was at the rear. 4) The project road width is 6 m, and full with large trees for good

environments. 5) There are two sub-buildings inside the prototype factory of crude palm oil

extraction with a complete cycle of bio-diesel productions and electrical generation. 5.1) Machine cover building: the width of 20 m, length of 42 m, height from

floor to the wall of 9 m. A cooling tower in gasifier is 19 m in height. Steel rolling door is at longitudinal wall in order to release heat from working machine. Windows are set to be at the mid-wall, opened by knocking. This improves better ventilation in the building that can be opened while raining because of the building eaves’ shape, and also allows the daylight shining. 5.2) The office building structure are made from reinforce concrete with width of 6 m, length of 8 m. Once the weight scale was set up, we could purchase and sell the palms at the office.


Executive Summary


Figure 4. Cover building layout

Figure 5. Entrance and exit of the project


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Figure 6. Office building, weight scale area and cover building

Figure 7. Front view of the cover building: cover building, palm storage area, and

weight scale office.


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Figure 10. Back view of the cover building: a place for receiving the palm oil and water treatment system.

Figure 11. Entrance of the cover building showing the steel rolling door for palm transportation.


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Figure 12 Inside the cover building: gasifier and control room.


Executive Summary


4.4 Design of wastewater treatment system The wastewater treatment system has been designed for crude palm oil extraction

with a complete cycle of bio-diesel productions and electrical generation. 5,000 l/day of wastewater from bio-diesel production with high COD (58190 mg/l) and BOD (3750 mg/l) is input to the system. After treatment, BOD must not exceed 200mg/l. The construction budget is 1,702,801.45 baht. Figure 13 shows the important working units.

Figure 13 Wastewater treatment system diagram

1) Collection sump: to store wastewater from the bio-diesel production. 2) pH adjustment tank: to adjust the wastewater pH, from collection sump,

equals to 7. 3) Acidification system: glyceride, tri-glyceride, and fatty acid are decayed to be

volatile fatty acid. 4) Anaerobic digester: a main wastewater treatment by non-air process using the

organic and inorganic anaerobic decays from microorganism. The resulted biogas is kept above the sump. The fermented water subsequently flows to the treatment unit

5) Sequence batch reactor: wastewater is treated by induced air flotation. The microorganism needs air to decay the organic and inorganic substances to obtain carbon

1 2 3 6 7

5 4


Executive Summary


dioxide, water and microorganism sludge. Water from fermentation will move to next treatment unit, and the microorganism sludge is later transferred to the sludge drying bed.

6) Sludge drying bed: to dry the sludge from the sequence batch reactor. Since the sludge is dry, it can be used further in agricultural process.

7) Polishing pond: to store the released water from the treatment system, adjust the water quality before releasing or be used after. 4.5 Design of crude palm oil extraction system Regarding the crude palm oil extraction system, our team has reviewed the recent information of crude palm oil extraction systems in Thailand, and analyzed the advantages and disadvantages. From the conclusions, the design guide lines are as follows.

1) Crude palm oil extraction is a non-steam system. Since the number of machines is less, no effects on environments, this extraction system can be set up in local community.

2) The extracted oil has to be A-grade. The production process is, therefore, to separate the palm pulp out of the palm seed before input to the crude palm oil extraction.

3) Regarding the energy consumption in crude palm oil extraction process, the steam extraction uses the lowest energy, but higher than those in the non-steam system since the wastewater treatment system is included. The lowest investment cost is the reduced palm humidity system by drying using heating rotating pipe.

4) Palm reidue and palm seed, resulted from the crude palm oil extraction process, will be further used as fuel for heating the palm drying in the production process and biomass production for the electricity generation.

Hereafter, the crude palm oil extraction process can be expressed as in Figure 14 and Figure 15 . The crude palm oil extraction procedure for biomass production using 9,142,369.90 baht of investment cost.


Executive Summary


Figure 14. Crude palm oil extraction process for bio-diesel production

Figure 15. Crude palm oil extraction procedure

1) 15 tones of fresh palm fruit bunch are poured from trucks, or 15,000 kg/day.

Staffs transfer the fresh palm bunches on conveyor number 15 that is taken by man power 2.5 ton of fresh palm bunch/hr, since the working hour is 6 hr/day.

2) 15 tone/day of fresh palm bunch are input to palm fruit bunch pulverized machine with capacity of 2.5 ton of fresh pal bunch/hr. To refine the fresh bunch, fresh palm fruit bunch are separated into 4 groups. The fresh palm fruit bunch from


Executive Summary


pulverized process is then transferred by conveyor number 6 to the storage tank number 10 with 2.5 ton of fresh palm bunch/hr.

3) The fresh palm fruit bunch is stored in tank number 10 with capacity of 35 m3 for 8-12 hours, in order to getting ripe and taking off from the branch easily.

4) The fresh palm fruit bunch is transferred by conveyor number 7 with 2.5 tones of fresh palm bunch/hr into Extraction of fresh palm fruit machine with capacity of 2.5 tones of fresh palm bunch/hr. The assumption are: fresh palm fruit bunch over 15 kg/bunch consists of water 12%, empty bunch 22% (by weight), and the rest is palm pulp. Therefore, the quantity of empty palm fruit bunch is equal to 0.55 ton/hr, and 1.65 ton/hr for fresh palm pulp.

5) Fresh palm fruit is transferred by chain conveyor number 8 with 1.65 ton/hr into fiber separation machine to take the entire palm branch, soil dust off, remaining only the palm fruit. The separated palm fruit is carried by chain conveyor number 12 into rotary palm drying machine with 1.65 tone of fresh palm fruit/hr at no less than 800C. The humidity in dried palm fruit must be less than 10% to stop the microorganism growth and fatty acid increase that will affect the crude palm oil quality.

6) Dried palm fruit is transferred by bucket elevator number 13 into crude palm oil extraction machine with seed split trunk type to separate seed, fiber, and oil. The assumption is: crude palm oil yield is equal to 17% relatively to the fresh palm fruit bunch weight. The extracted crude palm oil is A-grade, volume of 2,550 kg/day or 2,220 liter/day by the crude palm oil density is assumed to be 0.912 kg/l. Seed and fiber are further used for heating in palm fruit drying machine 2,025 kg/day.

7) The resulted crude palm oil is stored in tank number 15 before passed the filter press with 150 liter/hr to remove the sludge and contaminants and clean the oil before sending to bio-diesel process. The produced oil is about 2,109 liter/day with filter press loss at 5%.


Executive Summary


4.6 Design of biomass electrical generation From the review of electrical generation technology using biomass international

and domestic, the idea frameworks for design are as follows. 1) Fuel preparation: The fuel should be refine in order to increase the density,

consequently decrease the air volume in palm bunch, to obtain a high heat capacity fuel, and get better fuel movement in reactor.

2) Fuel gas reactor: The system simply operates and maintenance. Fix bed system is thus used. Gas flows down to decrease tar, and the resulted fuel gas can be further used in electrical generation using internal combustion engine.

3) Fuel gas cleaning and temperature decrease: The system has to be clean, simply maintenance, and spare parts are available or local material. The fuel gas cleaning is, therefore, water system by passing a venturi twice to remove the tar and decrease the fuel gas temperature. The fuel gas is then filtered by sawdust, sand, and activated charcoal.

From the idea frameworks, the comparison in performance, and economic optimum, the biomass electrical generating system using biomass capacity of 100 kW to be the Fix bed reactor, producing flow down gas with 15 ton/day of fresh palm fruit bunch, the empty palm bunch has a high humidity (58.6%). This empty palm bunch can be used as fuel to generate 115 kW of electricity using diesel engine as 120-kW generator. The cost is 15,400,831.00 baht, the detail is shown in Figure 16.


Executive Summary


Figure 16. Biomass electrical generation procedure

The components and equipments of the reactor are as follows.

Fuel elevator

Stoker

Fuel Storage and Heat Exchanger

Combustion Zone

Ash storage and remove zone

Air blower

Fuel gas treatment system - Heated has cyclone collector

- Heat Exchanger

- Dust and tar cyclone collector (2nd unit) - Temperature decrease and dust collector tower with venturi scrubber (1st unit) - Temperature decrease and dust collector tower with venturi scrubber (2nd unit)


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- Mist Eleminate

- Cooling Tower

Electrical generating system - Power engine - Electrical generator

4.7 Biomass fuel cutting machine According to the reviews and analysis of biomass fuel cutting machine, we can

define the efficient specifications of the cutting machine into 2 parts. 1) Fresh palm fruit bunch shredder: fresh palm bunch, separated from the palm

bunch split machine, is employed. The empty palm fruit bunch is equal to 0.55 ton/hr or 3,300 kg/day. The bunch size, not exceed 50 mm, is used to be fuel for biomass production.

2) 2,025 kg/day of fiber from the crude palm oil extraction is used as fuel for rotary drying machine. The resulted fiber is then put into biomass briquetting machine to be 6-10 inched and length over of 1 inch.

The specification of biomass fuel cutting machine and briquetting machine are as follows. 1) Biomass fuel cutting machine have to move by pulling, and readymade for assembly. The machine can pulverize (fresh) empty palm fruit bunch, or agricultural scraps. The body is made from SS440 steel or equivalent; endure corrosion, and rusty protection. The pulverize performance of (fresh) empty palm bunch is no less than 1 ton/hr, the (fresh) empty palm bunch can be refined with diameter of 3 inches, and used motor power engine. 2) Biomass fuel pelleting machine have to move by pulling, and readymade for assembly. The palm fiber is block molded, which is from crude palm oil extraction. The machine body is made from SS440 steel or equivalent; endure corrosion, and rusty protection. The block molding capacity is no less than 300 kg/hr. The pellet diameter is between 6-10 mm, length no less than of 1 inch, density no less than of 500 kg/m3, and use motor power engine.


Executive Summary


4.8 Design of transmission line and electrical connections The main operating system of electrical system in a prototype factory of crude

palm oil extraction with complete cycle of bio-diesel productions and electrical generation, are as follows.

1) Receive the entire power from PEA, no self-production 2) Receive power from PEA with partly self-production 3) The electrical power can be transmitted from generator to network of PEA.

Power distribution system is consisted of: (1) High voltage transmission 22 kV: receive and transmit power from the

distribution line 22 kV of the PEA. (2) One transformer with 400 kVA: convert the power voltage from 22 kV to be

low voltage of 380 V 3 phases, while receiving power from PEA for using in the factory and converting 380 V 3 phases back to be 22 kV into PEA network.

(3) Power supply: MDB power supply and power distribution control panel. (4) Electrical generator: be powered by 120-kW diesel engine. (5) Lighting system and sockets at in- and outdoor. (6) Fire alarming system (7) Building lightning system protection with lightning arrestor and bared

conductor, and ground system around the building (8) CCTV system: dome cameras installed in the factory, transmit the signal to

controller and record, with 19’ flat display monitor. (9) Electronic weight scale: read the weight and transmit to the scale system,

record and process program are set up at the system control. (10) The design of transmission line and electrical connections are shown in

Figure 17. The investment cost is 9,631,714.48 baht.


Executive Summary


Figure 17. Transmission line and electrical connections diagram.

4.9 Summary of crude palm oil extraction system with complete cycle of bio-diesel productions and electrical generation At this point, we can conclude as follows.

Crude palm oil extraction system with 112 kW can produce crude palm oil 2,109 liter/day, and empty palm fruit bunch 3,300 kg/day at working hour of 6 hr/day. The consume power is 782.99 kWh, and heat capacity of 11,664.18 MJ/day in the production process.

Biomass electrical generating system with 33.94 kW can generate power 2,760 kW/day at generator capacity of 115 kW, 24-working hours. The system use palm bunch fuel 3,300 kg/day.

Biomass fuel cutting machine with 14 kW can produce fuel pellet 2,2025 kg/day at generator capacity of 112 kWh/day, 6 working hours/day in the production process.

Bio-diesel production system with 82.6 kW can produce bio-diesel 2,000 liter/day at yield 95%, 8-working hours, and consumed power of 660.8 kWh/day.


Executive Summary


Wastewater treatment system with 2.15 kW can support wastewater from bio-diesel process 5 m3/day at 8-working hour/day using power of 17.20 kWh/day.

Energy cost for crude palm oil process is 1.36 baht/liter at power rate of 3.50 baht/kWh Figure 18. Schematic diagram of produced and consumed energy in crude palm oil extraction system with complete cycle of bio-diesel productions and electrical generation 5. Biding documentary 5.1 Bidding documents has illustrated the information of cover building, wastewater treatment system, crude palm oil extraction system, biomass electrical generating system, and transmission line and electrical connections. Our team has finished the documents and submitted 50 copies to DEDE, the detail is as follows.

1) Plan drawing 2) Specification 3) Work load and price lists

4) Median price 5.2 Bidding documents has illustrated the biomass fuel cutting machine. Our team has finished the documents and submitted 50 copies to DEDE, the detail is as follows.

1) Specifications 2) Work load and price lists

ระบบสกัดน ้ามันปาล์มก าลังไฟฟ้าติดตั้ง 122 kW

พลังงานความรอ้นในการอบแหง้ 11,664.18 MJ



ผลปาล์มสด 15,000 kg

ปรมิาณการใช้พลังงานไฟฟ้า782.99 kWh

เครือ่งตัดทอนเชื อเพลิงชีวมวลก าลังไฟฟ้าติดตั้ว 14 kW


ปรมิาณการใช้พลังงานไฟฟ้า

112 kWh

ทะลายปาล์มเปล่า 3,300 kg/day

น้ าเสีย ปรมิาณ 5 m3/dayCOD 58,190 mg/lBOD 37,500 mg/l

เชื้อเพลิงอัดแทง่2,025 kg/day36,166.5 MJ

ระบบผลิตแก๊สชีวมวลก าลังไฟฟ้าติดตั้ง 33.94 kW

ก าลังไฟฟ้าติดตั้งที่ผลิตได ้115 kW




2,085.34 kWh

ระบบผลิตไบโอดีเซล2,000 Liters/day

Yield 95%ก าลังไฟฟ้าติดตั้ง 82.60 kW



CPO2,109 Liters ไบโอดีเซล

2,000 Liters

ปรมิาณพลังงานงไฟฟ้าทที่ผลิตได้

2,760 kWh

ระบบบ าบัดน้ าเสียก าลังไฟฟ้าติดตั้ง 2.15 kW



กากใยปาล์ม 2,025 kg/day


ก าลังไฟฟ้า17.20 kWh

น้ าเสีย ปรมิาณ 5 m3/dayCOD 300 mg/lBOD 200 mg/l










112 kWh









2,085.34 kWh










112 kWh


















112 kWh









2,085.34 kWh





CPO2,109 Liters ไบโอดีเซล

2,000 Liters

ปรมิาณพลังงานงไฟฟ้าทที่ผลิตได้

2,760 kWh




กากใยปาล์ม 2,025 kg/day


ก าลังไฟฟ้า17.20 kWh

น้ าเสีย ปรมิาณ 5 m3/dayCOD 300 mg/lBOD 200 mg/l

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