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TRANSCRIPT
Date : 21st April 2011
Venue : PNB Darby Park, KL
PRESENTATION STRUCTURE
• FRIM
• Paper Mill Sludge Pellet
• Drum Method for Carbonization
• Rice Straw Pellet System
• HTD for Rubberwood and Tropical Hardwood
• Conclusion
FRIM
• Established 1929
• Statutory body
• Malaysia Forestry Research and Development Board under the Ministry of
Primary Industries in 1985 (Act 319)
• In 2004, moved to Ministry of Natural Resources and Environment
• Carry out R, D & C across the forestry
value-chain
FRIM
• Five research divisions:
• Forestry
• Product Development
• Biotechnology
• Natural Products
• Conservation of Forest Biodiversity
• With 5 other supporting divisions.
Vision & Mission
• Vision
To make FRIM a world-class tropical
forest research institute
• Mission
To achieve excellence in scientific
research, development and forestry services
Pellets from Paper Mill Sludge
INTRODUCTION
•Malaysia,
• 1 million metric tonnes of sludge generated
• Innovation
• Industrial Sludge Fuel Pellets
• Recycling Industrial fiber wastes into briquettes
• Environmentally Friendly Product can be widely used in industry – boiler feedstock
PELLETS FROM PAPER MILL SLUDGE
THE INNOVATION
•Producing Pellets from sludge ----� Environmentally friendly method of disposing sludge
•Pellets = converting loose material (saw dust) into a compact shape sans binder through compression
•Creates a new opportunity for the paper industries
PELLETS FROM PAPER MILL SLUDGE
• Penggunaan 100% bahan enap cemar kertas
• Pembuatan produk pellet yang di hasilkan kepada saiz yang diperlukan.
• Produk alternatif kepada kayu sebagai bahan
bakar• Mengeksploitasi penggunaan bahan enap cemar
yang terhasil sebagai bahan produk nilai tambah.
UniquenessBahan enap cemar
Proses pengeringan
EC pellet
Campuran
Proses pemampatan
Flow Chart EC PelletEC 70:30 50:50
Kandungan lembapan (%) 7.5 4.0 4.3
Ketumpatan (kg/m3) 150 1223 1176
Bahan meruap (%) 52.1 67.4 62.9
Kandungan abu (%) 40.1 21.8 16.5
Kandungan karbon (%) 7.8 10.8 20.6
Kandungan kalori (MJ/kg) 5.2 11.7 13.1
• Bersih dan mudah dikendalikan• Mempunyai ketumpatan yang lebih tinggi
• Mempunyai bentuk dan saiz yang seragam• Meningkatkan lebih daripada 10 isipadu sisa• Tempoh penyimpanan lebih lama
• Pembakaran yang sekata dan lengkap • Membuka peluang yang menguntungkan kepada
industri kertas yang menghadapi masalah
pelupusan bahan enap cemar.• Kaedah pelupusan yang mesra alam.
Advantages
Drum Method for Carbonization• Charcoal is a carbonaceous solid with a fixed
carbon content of 70% or more• The drum method is suitable for the production of
coconut shell charcoal.
• The major drawback is the emission of large quantity of smoke and tar during carbonisation process which makes it environmentally
hazardous• The other problems pertained to the quality and
uniformity of the charcoal produced
Introduction
Innovation
• Charcoal in a Simple, Quick, Efficient, and
Economic kiln. • reduce emissions and its greenhouse effect.• It also and can be constructed in a suitable sizes
by local materials. • Environmentally friendly, productive and
economical for charcoal production in Malaysia
• Clean and easier handling• Complete carbonisation• Efficient – quality & quantity
• Low cost• Environmental friendly
Advantages
Comparison
EFDM Drum
Carbonisation (hours) 22 24
Charcoal (kg) 32 18
Efficiency (%) 40 20
Cost (RM) 60 50
Moisture content (%) 6.1 12.5
Volatile matter (%) 12.4 21.0
Ash content (%) 2.3 2.5
Fixed carbon (%) 85.3 76.5
Calorific value (MJ/kg) 32.7 31.0
Products
Rice Straw Pellet Introduction
• Rice straw is the dry stalks of rice plants, after
the grain and chaff have been removed. • More than 1 million tonnes of rice straw are
produced in Peninsular Malaysia annually.
• Burning in the open air is the common technique of disposal that contribute to air pollution.
Process
• Pellets are a type of solid fuel, generally made
from compacted residues. • Pellets are produced by compressing the
residues which has first passed through a crusher
to provide a uniform mass. • They are usually produced as a byproduct of
agricultural activities.
• The pellets are extremely dense with low moisture content that allow them to be burned with very high combustion efficiency.
Properties
Straw Wood Oil palm
Moisture content (%) 7.5 7.5 5.9
Volatile matter (%) 71.3 82.8 88.2
Ash content (%) 12.8 1.2 4.2
Fixed carbon (%) 8.4 8.5 1.6
Density (kg/m3) 1060 1265 982
Calorific value (MJ/kg) 15.8 19.1 19.7
• Uniform in size and quality
• Easy to transport and store• The process increases the net calorific value of
material per unit volume
• The process often helps to solve the problem of residues disposal
• The process helps to reduce deforestation by
providing a substitute for fuel wood
Advantages
Process of EFB for Biodegradable Container
• Industry Sector
Eco-Products ;
Environmental Services
Introduction
• In Malaysia, food containers, industrial packaging and medical utensil are mostly made from plastic
either from polylactide (PLA) or polyethylene terephthalate (PTE).
• Products made from plastic are not environmentally friendly due to their difficulty in composting, and costly due to the escalating
price of petroleum.
• In developed countries, these products are made
from lignocelluloses fibres that are biodegradable.
Agricultural Residues
• Malaysia is blessed with abundant supply
of natural fibres.
• There are million of tones of agricultural residues that can be used as a raw
material to produce such moulded pulp packaging products.
• Moulded pulp packaging is made from pulp which is moulded into a shape designed to
hold and protect the products to be packed.
Oil Palm Biomass
• Oil palm biomass, the most abundant fibre resource, is readily available from existing oil palm plantations and palm oil mills.
• Each year, the oil palm industry generates approximately 13.9 million tonnes of moisture-free cellulosic materials to act as renewable and permanent feedstock raw material for the production of paper pulp.
• Thus, oil palm biomass that includes oil palm trunk (OPT), oil palm fronds (OPF) and empty fruit bunches (EFB) could become supplementary fibre sources of short-fibered pulps that traditionally has been produced from hardwoods.
FlowchartExamples of moulded products can be made by oil
palm biomass.
HTD System for Rubberwood and Tropical
Hardwood
32
DESCRIPTION OF THE TECHNOLOGY
Description of Product (s)
THE ESSENTIAL SYSTEM FEATURES CONSISTS OF,
• Main HTD Chambers built-up of proprietary K-Block panels- light weight with sufficient stiffness to limit deformation under high
temperature.
• The handling line is a platform trolley holding timber packs which are
forklift-loaded.
• A physical restraint protocol is also incorporated to ensure quality
throughput of lumber batches.
• The humidification system to provide both the steam spray and water
spray (at ambient temperature) which are essential stages of HTD protocol.
Con’t… Description of product
• Pneumatic control ventilation system.
• Industrial PLC (programmable logic controller)
instrumentation which coordinates the monitoring and
controlling of various parameters as specified by the HTD protocol
• Uniform cross-flow air circulation through timber stacks at high speed of 2.5 to 3.5 m/s
34
IBS HTD STRUCTURE
35
IBS HTD STRUCTUREProperties of HT-dried Rubberwood
Reduced warping in timber
Enhanced grain feature
Better dimensional stability
Slight increased in specific strength
Production Volume
• 14 ton per kiln per 1-day cycle
• 1,260 ton per month
• 15,120 ton per year
Standard and Regulation
• Compliance with EU Directives
– Categorisation of borates under “Reprotoxic Category 2”
under the Dangerous Substance Directive (67/548/EEC)
MANUFACTURING ASPECT
37
PROPOSED SELLING PRICE & MANUFACTURING COST
AND
COMPARISON WITH AVAILABLE PRODUCT IN THE MARKET
• Proposed Selling Price RM 1,430/t
• Manufacturing Cost RM 1,267/t
• Profit Margin RM 163/t
Custom HT-Drying Service Charges
• Proposed Service Charges about RM 300/t
Customised HTD System Package
• Proposed Selling Price RM 5-6 million per package
39
MARKET POTENTIAL
Current Drying Practice in Malaysia
95% 5%
Conventional
System
(Temp < 80 degC)
Others
WHAT ARE THE MARKET SIZE – LOCAL & INTERNATIONAL
Targeted replacing 40% of existing conventional system in Malaysia
125 (51%)74 (30%)
47 (19%)
Kiln Drying Plants in MalaysiaPeninsular MalaysiaSabah
Sarawak
Midterm, TWI will explore the export market in the Asia Pacific Regionespecially Indonesia, Vietnam, India and China.
Source: MTIB
Some of the much improved attributes arisen from FRIM innovation are,
� Reduced negative impact on the environmentHTD system offers an alternative solution to use of chemical preservative
borates via use of high-heat treatment technique.
� Energy-efficient systemThe HTD time for 30 mm-thick sawn dimension stocks is reduced to
about 2 days compared to conventional drying which requires 14-16 days.
� Cost-efficient operationA techno-economic study shows that a complete HTD plant can be set
up with a capital investment comparatively less than that required for
setting up a conventional drying plant. The comparisons are based on the same overall production capacity, designed for both types of kiln
system.
n WHAT IS THE ADVANTAGE/DISADVANTAGE
�Enhanced timber quality• Minimise warping via a physical restraint protocol to maintain a
straight-form sawn timber.
• Enhanced wood grain feature and a more uniform albeit darker colour throughout the lumber.
• Increased dimensional stability - has lower equilibrium moisture content (EMC), less movement (shrink and swell due to
fluctuating ambient moisture) under general service condition.
PHOTO OF THE PROTOTYPE
HTD SYSTEM
Products produced from HT-dried rubberwood
CONCLUSIONCONCLUSION
� Environmentally friendly
� Cost-effective
� Just in time (JIT) stock holding
� Energy efficient
� Enhanced timber quality
� HTD the solution to chemical free rubberwood
� Ensures Malaysia’s continued dominance in the
rubberwood industries.
Bil Researcher Division Title of Invention
1 Puad Elham Forest Products Versatile Charcoal Briquette Machine
2 Mohd Nor Mahat Forestry Biotechnology Torrified Acacia Wood As Bio-Coal (FRIM TRAW)
3 Abdul Rashid LiNatural Resources
Products
Pectin-Rich fraction of Morinda Citrifolia as
glucose lowering agent
4 Dr Rushdan Ibrahim Forest ProductsConverting oil palm empty bunches into all types
of alkaline pulps for different types of paper
5Dr Nor Azah Mohamad
AliNatural Products
Natural based essential oil product with potential
adulticidal effects
6Mohd Shahidan Mohd
ArshadNatural Products
Standardised Tinospora Extract (Tinosporex™)
with anti-hypercholestrolemic property
7Dr Mohd Khairun
Anwar UyupNatural Products Phenolic-Treated Plybamboo (PTP)
8 Dr Nor Hasnida Hassan Forestry BiotechnologyInduction of hairy root culture from Tongkat Ali
explants using Agrobacterium rhizogenes
Bil Researcher Division Title of Invention
9 Dr Nor Hasnida Hassan Forestry BiotechnologyProduction of Tongkat Ali bioactive
compounds from hairy root culture
10 Dr Hasnida Hassan Forestry BiotechnologyMicropropagation of Tongkat Ali using
tissue culture techniques
11 Dr Hasnida Hassan Forestry Biotechnology
In vitro propagation of Aquilaria hirta
(Chandan) using tissue culture
techniques
12 Dr Hasnida Hassan Forestry BiotechnologyMicropropagation protocol of Mas
Cotek (Ficus deltoidea)
13Dr Wan Tarmeze Wan
AriffinForestry Biotechnology
Bamboo-Oil Palm hybrid Engineered
Lumber (B-POPS™)
14 Dr Hasnida Hassan Forestry Biotechnology
In vitro propagation of Aquilaria
malaccensis (Karas) using tissue culture
techniques
15Dr. Wan Tarmeze Wan
AriffinForestry Biotechnology
Enginneered lumber from crushed and
dismantaled bamboo material
16 Dr. Mohd. Ilham Adenan Forest Biodiversity
ECfC 06: a standardized extract of
Erythroxylum cuneatum forma
cuneatum (Miq.) Kurz (cinta mula) as
herbal remedies for addition therapy.