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Energy Recovery From Wastewater Treatment: A Case study in the Biomethanation of palm oil mill effluent
BRUNEI DARUSSALAM COGENERATION WEEK 2004
23-24 November 2004 The Centrepoint Hotel, Bandar Seri Begawan
Harvesting Oil Palm Fruits
SIRIM Environment & Bioprocess Technology Centre Shah Alam, Selangor, Malaysia
Dr. B. G. Yeoh
Oil Palm Fresh Fruit Bunches
Environment & Bioprocess Technology Centre
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Planted area No. of mills
Malaysian Palm Oil Industry
122 (1977) → 368 (2003) 57,000,000 tonnes fresh fruit bunches
291,000 ha (1970) → 3,750,000 ha (2003)
Production (2003)
12,220,000 tonnes crude palm oil (48% world output) 1,480,000 tonnes palm kernel oil Exports (2003) 1,120,000 tonnes palm oil (USD 4,470 mil) 700,000 tonnes palm kernel oil (USD 316 mil) Volume of POME Treatment method used 30.6 85% 55% 33% 12% - 42.8 x 106 m3 (2003) ponding systems GHG emission (CH4, CO2) water-course discharge land application both
Oil Palm Plantation Stretching Endlessly
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Treatment efficiency
19% non-compliance
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Wastewater Characteristics
Parameter Temp (°C) pH O&G BOD COD TS SS TVS NH3-N TKN K Mg Ca Zn Fe Cu POME 80-90 4.7 4,000 25,000 50,000 40,000 18,000 34,000 35 750 2,270 615 439 2.3 46.5 0.89 Discharge Standard 45 5.0-9.0 50 100 (50) 400 150 200 Standard A
(Drinking water intake points)
Standard B
(All other points)
40 6.0-9.0 ND 20 50 50 1.0 1.0 0.20
40 5.5-9.0 10.0 50 100 100 1.0 5.0 1.0
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Anaerobic Digestion Technology A versatile and cost-effective waste treatment technology, particularly for the primary treatment of high-strength organic and agroindustrial wastes Ready options for resource recovery and utilisation besides achieving the waste treatment objective Methane-rich biogas produced as a byproduct of the process readily exploitable as a biofuel for heat and power generation Nutrient recovery from the digested liquor as fertiliser Low process energy requirement and high process stability particularly in terms of toxicants and load changes
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Lagoon Systems Commonly Used in POME Treatment
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The Biomethanation Process
Complex organic molecules (e.g. polysaccharides, fats)
Hydrolytic bacteria
Monomers (e.g. glucose, amino acids, fatty acids)
Fermentative acidogenic bacteria
Organic acids, alcohols, ketones
Acetogenic bacteria
Acetate, CO2, H2
Methanogenic bacteria
Methane (CH4)
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Gas yield from anaerobic digestion of POME at various reaction temperatures in a pilot plant study
Design Basis
45 240 - 450 25,000 5,000
Reaction temperature (°C) 35 45 50 55
Biogas yield (m3kg-1-BOD added) 0.78 0.92 0.99 1.41
CH4 yielda (m3kg-1-BOD added) 0.47 0.60 0.65 0.92
Mill capacity (t-FFB h-1) Wastewater load (m3d-1) Influent BOD (mgL-1) Maximum digester effluent BOD (mgL-1)
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Operating Parameters for Economic Analysis
Digestion temperature (°C) Minimum retention time (d) Minimum effective reactor volume (m3) Hydraulic retention time (d) Expected digester effluent BOD (mgL ) BOD loading rate (kgm-3d-1) Biogas production rate (m3m-3d-1) Annual biogas production (m3year-1)
Environment & Bioprocess Technology Centre
-1
45 10.9 4,950 20.6 – 11.0 1,230 – 4,890 1.21 – 2.27 1.11 – 2.09 2.56 x 106
50 9.2 4,150 17.3– 9.2 2,500 - 5,000 1.45 – 2.71 1.44 – 2.68 2.77 x 106
55 7.0 3,200 13.3 – 7.1 2,320 – 4,910 1.88 – 3.52 2.65 – 4.96 3.94 x 106
Cost-Benefit Factors
Annual Operating Revenue
(contd.)
♠Energy recovery from biogas - Heat energy (fuel oil equivalent) - Electricial energy (electricity value) ♠Nutrient recovery from digester effluent - Fertilisers (inorganic fertilisers equivalent)
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Cost-Benefit Factors
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Capital Costs and Capital Charges
♣Anaerobic reactor system and accessories (civil works, pump sets, piping and electrical works) ♣Biogas storage system ♣Gas-engine generators ♣Land application system
Cost-Benefit Analysis (in USD): Systems utilising biogas for heat generation and land application of digester effluent
45 609,050 52,620 95,950 335,880 187,310 30.8 2.5 50 579,890 50,100 93,130 359,090 215,860 37.2 2.2 55 591,840 51,130 94,290 488,400 342,980 58.0 1.5
EC-ASEAN COGEN Programme Phase III
Reactor temperature (°C) Capital cost Annual capital charges Annual operating & maintenance cost Annual operating revenue Annual cost-benefit Annual return on investment (%) Payback period (year)
Annual Operating & Maintenance Costs
♥Labour ♥Consumables ♥Utilities ♥Maintenance cost as percentage of installed equipment cost [3%, 3%, 5%, 2%]
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Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration
Cost-Benefit Analysis (in USD): Systems utilising biogas for electricity generation and land application of digester effluent
Reactor temperature (°C) Capital cost Annual capital charges Annual operating & maintenance cost Annual operating revenue Annual cost-benefit Annual return on investment (%) Payback period (year) 9.6 8.6 6.7 315,220 21,790 1.8 336,740 37,620 3.0 455,960 98,160 6.4 45 1,229,050 106,190 187,240 50 1,249,890 107,990 191,130 55 1,541,840 133,210 224,590
The Palm Oil Milling and Refining Complex
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(The KS System)
A View of the Floating Top Closed-Tank Anaerobic Digester Closed[Capacity = 7,500 m3, HRT = 18 days]
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Biogas Output from the Anaerobic Digestion System
30 MT/hr FFB Plant: • • • Estimated total methane production:
6,160 Nm3day-1 (11,120 m3/day biogas at 308K)
Prospects for Commercialisation
Policy Aspects
Current fuels used in electricity generation: Natural gas (71%), Hydro (12%), Coal (9%), Fuel oil (8%) New Policy - Renewable energy as fifth fuel targeting 5% of total electricity generation by 2005 (500 MW) – Small Renewable Energy Power (SREP) Programme launched 11 May 2001
Energy Value of 1
Nm3
Methane:
35,800 kJ; 8,550 kcal; 33,930 Btu; 9.94 kWh
Energy Rate of Methane Produced per day
2.2 x 108 kJday-1 5.3 x 107 kcalday-1 2.1 x 108 Btuday-1 6.13 x 104 kWhday-1
RE sources: Biomass, Biogas, Solar, Municipal Solid Waste, Minihydro, Wind
Power generation at 40% efficiency: 1.02 MW
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CDM business opportunities under Kyoto Protocol
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Savings from Biogas Usage in the Refinery Operations
Renewable Fuel Biogas Equivalent Fuel Substituted Diesel Fuel Quantity (Lday ) 4,000
(2 units high pressure steam boilers)
-1
Savings (USD year ) 264,000
-1
Greenhouse Gas Potential of Lagoon Systems Used in POME Treatment
Total amount of CH4 evolved: 375 x 106 m3 (at 35oC) = 225 Gg [equivalent to 5,170 Gg CO2, or 3.6% of total]
Medium fuel oil
2,500
(1 unit conventional steam boiler)
150,000
Total savings
• • Typical mill operation: 300 days per annum
414,000
Inventory of greenhouse gas emissions in Malaysia: 2,231 Gg CH4 144,000 Gg CO2
Diesel Fuel: USD 0.22 (RM0.84)/L; Medium Fuel Oil: USD 0.20 (RM0.76)/L
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Methane Capture Achieves Greatest Carbon Efficiency: Methane possesses GWP of 21 (1 tonne of methane released exerts global warming effect equivalent to 21 tonnes of CO2) Installed assets generate greater returns in terms of emission reductions 1 MW of baseload power generated from fugitive methane (8000 h yr-1) can earn between 25,000 to 40,000 tonnes of CERs In financial terms, an additional revenue of between USD 100,000 and 160,000 per MW capacity could be realised annually based on USD 4 per tonne of CO2
Environment & Bioprocess Technology Centre
Conversion of the Ponding System to the Anaerobic Reactor System ♦ Advantages
• • • • • Recovery of methane as an energy source GHG emission reduction convertible to carbon credits Valuable land-use space reduction Higher waste treatment efficiency Improved environmental quality
♦ Disadvantages
• • • • Higher capital outlay Excess energy sources available in the palm oil mill Value of biogas realisable only from direct off-site use Small scale as an energy plant
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Carbon Emission Reduction
(The KS System)
Source Renewable Fuel Biogas Carbon Emission Reduction
(t CO2-eq year -1)
Methane emission reduction
(1,407 t year -1)
29,547
Diesel substituted
(4,000 Lday-1)
2,877
(2,500 Lday-1)
Medium fuel oil substituted
2,115
Total
34,539*
*Potential CER value of USD 138,156 @ USD 4.00 per tonne CO2
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