organic matter management and the potential 2/day … · organic matter management and the...
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Organic matter management and the potential
for the biogas sector in the Malaysian agro-
industrial sector - BIOTEC case study of
palm oil mills
Biogas Asia Pacific Forum
Kuala Lumpur June 2013
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OVERVIEW
1. Introduction
2.Malaysia, agricultural country
3.Organic matter, pillar of the POM industry
4.Case studies of OM management for POM
5.Conclusions
6. Q&A
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Why organic matter management ?
• Malaysia in its context agro – industrial context
• Agro-industries and organic matter: link
• Tropical countries and OM production
• Tomorrow’s challenges (environment, energy, food, diversity)
• OM cycle and human activities integration
1. INTRODUCTION
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1. INTRODUCTION
OM cycle
• Creation (photosynthesis), transformation, breakdown
• Different forms (solid, liquid, gas)
• Natural cycle and human activities
• Main impact: agriculture and related industries
• Growing, transforming, contaminating, recycling
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2. MALAYSIA & AGRICULTURE
Malaysia’s agriculture in a nutshell
• Arable land ~ 24% of country’s territory
• Main products: palm oil, rubber, kernel, paddy, fruits
• Second largest CPO producer in the world
• Third largest rubber producer in the world
• Oil palm > 70% of arable land in Malaysia (5m ha)
• Agriculture = 10% of GDP and Plantations ~ 7% of GDP
Malaysia’s agro-industrial sector is important
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2. MALAYSIA & AGRICULTURE
Malaysia Agricultural Land use (FAO 2010)
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2. MALAYSIA & AGRICULTURE
Malaysia Agricultural ranking (FAO 2010)
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2. MALAYSIA & AGRICULTURE
Malaysian oil palm agro-industry
• Related to the main crops (CPO mills, refineries, rubber mills)
• Stability of climate, political stability
• Controlled market (MPOB e.g.) and international commodities
• Relatively young agro-industry and modern processes
• Large impact of perennial crops (oil palm, rubber)
• Both centralized (ports) and delocalised (estates)
• Good communication & transport infrastructure
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3. OM = CROSS ROAD
AGRICULTURE – ENVIRONMENT - ENERGY
• OM related to all three fields
- Production + food
- Transformation – sub products
- Contamination generated during agro-indus. processes
- Energy needs and production (renewable vs fossil)
• Agro industries:
- Require feedstock and transform it
- Require energy
- Generate sub-products and contamination
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3. OM = CROSS ROAD
AGRICULTURE – ENVIRONMENT - ENERGY
• OM pivotal role
• Comes from the crop
• Returns to the crop ? Which fraction ?
• What sources of energy do we use in our agro-industries ?
• Is the organic matter cycle closed ?
• Can agro-industries become energy providers for other sectors ?
Not one single solution but a technological package…
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4. CASE STUDIES
TOOLS to MANAGE OM
• Waste water treatment and energy generation (Liquid)
• Composting and ferti-irrigation (solid / liquid)
Palm oil mill case studies:
1. Waste water treatment and biogas generation in palm oil mill
2. Ferti – irrigation & Composting in oil palm estates
Importance of INTEGRATED SYSTEMS
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MILL
60 TFF/h
OIL
POME
BIOGAS
BIOLOGICAL ANAEROBIC SLUDGE
TREATED
EFLLUENT
FLARE
BIOGAS ENGINE 2MW
Existing lagoons
LAND APPLICATION
210 000 m3/y
350,000 eq. hab 210 000 m3/y
200 000 m3/y
10 000 m3/y
3 600 000 Nm3 CH4/y
6 000 000 Nm3 biogas/y
12 M kWh / y
0,7 m3/TFFB
60 kg COD/m3
BIODIGESTOR
11 Nm3 CH4/TFFB
Approx. 5 % of
biogas production
per year
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4. CASE STUDIES
BIOTEC & organic matter management
Energy
Environment Agriculture
Engineering (Consultancy, design,
project management)
Construction (procurement, supervision,
commissioning)
Operations &
Maintenance (of implemented
plants)
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4. CASE STUDIES
BIOGAS (energy – environment)
• For agro-industries which produce organic contaminated wastewater
• Anaerobic digestion and production of biogas
• Effluent treatment and energy generation
• Production of heat, electricity or CBG
• Reduction of green house gases (CH4)
• Importance of energy prices and regulatory framework
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4. CASE STUDIES
BIOGAS
• Palm oil mill in Malaysia: approx. 400
• Biogas plants = proven technology
• Biogas and energy generation (heat, diesel replacement, electricity, CBG)
• Improve environmental standards (wastewater, boiler emissions)
• Implement sustainable and profitable plants
Importance of DOE framework
Importance of SEDA / TNB framework
Importance of the COST OF ENERGY
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No. of large
POM biogas
plants with
BIOTEC
technology Electricity
Generation
12 MW 70,000,000 kWh
Africa
Asia
Latin
America
4. CASE STUDIES
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4. CASE STUDIES
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4. CASE STUDIES
BIOGAS
• Palm oil mill biogas plants
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4. CASE STUDIES
BIOGAS
• Palm oil mill biogas plants
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4. CASE STUDIES
BIOGAS
• Palm oil mill biogas plant
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4. CASE STUDIES
BIOGAS
• Palm oil mill biogas plant
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4. CASE STUDIES
BIOGAS
• Palm oil mill biogas plant
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4. CASE STUDIES
BIOGAS - perspectives
• Malaysia ~ 400 POM
• Considering 1,5MW per mill of electricity generation
• Approx. 600MW of renewable energy
• Malaysia yearly electrical consumption ~ 100 billion kWh
• Total green electricity from POM ~ 3 - 4% of the total country consumption
• Importance of infrastructure development
• Future renewable natural gas grids…?
• Importance of the regulatory frame work and tariffs
• Importance of the cost of energy in the country
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4. CASE STUDIES
FERTI-IRRIGATION & CO-COMPOSTING
(agriculture – environment)
• Key concept: return nutrients and organic matter to the crop
• Technologies are complementing each other
• Ensure a sustainable usage of sub-products
• Palm oil mill could export =
Food (CPO)
Energy (biogas, biomass)
Organic fertilizer (Ferti-irrigation / compost)
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4. CASE STUDIES
FERTI-IRRIGATION
• For agro-industries which produce waste water
• Waste water treatment needed to stabilise organic matter
• OM mineral matter = nutrients (NPK)
• Nutrients absorbed by soil and crops
• Increase yields through:
- Irrigating (especially during dry season)
- Fertilizing (organic fertilizer)
• Savings on conventional chemical fertilization
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4. CASE STUDIES
FERTI-IRRIGATION
• Treated effluent in palm oil estate (Aguan – Honduras)
• 200 ha palms of under monitored & controlled organic fertilization
• 80% replacement of chemical fertilizer
• 8% of FFB yield increase in 2 years
• Importance of nutrient (NPK) and water balance
• Low investment cost (approx. RM 5,000/ha)
• Chemical fertilization savings: approx. RM 1,500 / ha-year
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4. CASE STUDIES
FERTI-IRRIGATION
• Treated effluent in palm oil estate (Aguan – Honduras)
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4. CASE STUDIES
FERTI-IRRIGATION
• Treated effluent in palm oil estate (Aguan – Honduras)
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4. CASE STUDIES
CO-COMPOSTING
• For EFB + anaerobic sludge + ashes
• Transformation of organic matter to readily available organic fertilizer
• 50% reduction of EFB transport cost
• Turning windrow composting (open or closed system)
• Compost used on estate to replace chemical fertilization
• Increases of yields and palm’s health
• 45 to 60 days process
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4. CASE STUDIES
CO- COMPOSTING
• Palm oil mill in Colombia
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4. CASE STUDIES
CO-COMPOSTING
• Palm oil mill in Colombia
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4. CASE STUDIES
ORGANIC FERTILIZATION - perspectives
• Malaysia ~ 400 POM
• Considering 1,000ha of organic ferti-irrigation per POM
• Considering 1,500ha of organic compost per POM
• 1,000,000ha equivalent to 25% of oil palm planted area
• Savings of approx. RM 1,500 ha/y of chemical fertilizer
• Savings for the industry of RM 1.5b / year
• Organic fertilization over one plantation cycle (25 years)
~ RM 37 billion saved in the country
• Importance of regulatory framework (DOE)
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5. CONCLUSIONS
From an energy point of view
• Increased pressure on fossil energy sources
• Steady increase of prices of oil and fertilizers
• Focus on renewable energy
• Re-engineer our energy production sector (delocalised small power plant in a national grid?)
• Electricity and/or CBG ?
• Further uses of biomass and energy conversion
- Biofuels (biodiesel)
- Dry anaerobic digestion
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5. CONCLUSIONS
From an agricultural point of view
• Engineering solutions manage OM = sustainable farming systems
• From the crop to the crop (nutrients)
• Integration agro-industries farming for OM transfers
• Re-engineer fertilization & irrigation systems (organic & efficient)
• Health of soils in the long term
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5. CONCLUSIONS
From an environmental point of view
• Engineering solution to recycle OM and water
• Engineering solutions to add value to
• Increase in environmental protection and compliance of agro-industries (water, solid and air)
• Importance of global warming on crops (feedstock for industry)
• Importance of global warming and reduction of GHG
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6. QUESTIONS & ANSWERS
THANK YOU FOR YOUR ATTENTION !
Baptiste Kervyn
CEO
Biotec International Asia Sdn.
Bhd
Web: www.bio-tec.net
Tel: +60 3 87 37 37 00
Email: [email protected]