How can the extraction of palm oil be improved and at the same time prepare the biomass for the milling process to produce glucose and xylose.

Transcription

1 How can the extraction of palm oil be improved and at the same time prepare the biomass for the milling process to produce glucose and xylose. Dr. Azis Ariffin

2 Do you know that palm oil milling process is actually a process to produce glucose and its little sister xylose. And coincidently the more glucose we produce, the more oil we recover! And that almost all the glucose from the fresh fruit bunch (FFB) is produced during the sterilization process. Glucose is pleasantly sweet and quite expensive. Its little sister xylose is more expensive. And just to remind you that in the palm oil mill, the more glucose we produce the more oil we recover. Azis

3 FFB There is no free glucose and xylose in FFB. Azis

4 C e l l u l a r m o r p h o l o g y o f f r u i t m e s o c a r p Azis

5 Mesocarp cells and fibers Plasmalema (Hemicelluloses) Cytoplasm (oil body & water) Fiber (lignified cellulose) Cell wall (alpha-cellulose) Morphology (include cross-sections) of mesocarp cells. Dr. Azis

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7 2 most important organic compounds (oil and carbohydrate) in FFB In the mill hemicellulose expresses most chemical changes. The more the merrier. In the mill oil expresses least chemical changes. xylose glucose oil lignocellulose fiber xylose glucos e

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9 Under the current circumstances all we want is just the oil. Every palm oil mill around the world gets the oil but quantity-wise is never satisfied. There has always been attempts of palm oil millers to improve their OER. Numerous attempts to improve OER have been made but the OER, seventy years ago, yesterday, now, tomorrow, perhaps, in future will still remain glaringly similar. Current predicaments USB ~ 5% High oil in pressed fiber High oil in effluent Ripeness of FFB Unsatisfactory OER Azis

10 Partially treated effluent This effluent pond Oil and grease mg/liter Oil and grease >200mg/liter Cellulose (%) 52.2 /- 6.5 Hemicellulose (%) 28.8 /- 1.1 Lignin (%) 17.1 /- 3.6 Cellulose (%) > 55 Hemicellulose (%) > 30 Lignin (%) ~ 15 Contributor of low OER: oil in ponds Excessive oil loss as observed in the first and second effluent ponds. Azis

11 H o w ca n t h e ex t r a c t i o n o f p a l m oil be improved Azis

12 OER 70 years passed and now Thailand ~18% OER (oil extraction rate) Pen. Malaysia ~20% Sabah Sarawak Malaysia/Kalimantan Indonesia ~22% Sumatra Indonesia ~24% Better process management and automation are realized for palm mill processing. Better milling appliances/devises (e.g., boilers, turbine, sterilizers, thresher, pumps, automations, etc.) are being used. Nonetheless, OER of the respective geographical locations continues to virtually remains the same. Why? Azis

13 Enhancing oil recovery via Chemical innovations Made possible by the milling contraptions Get the respective processing (ramp, conveyer, sterilizer, digester, press, vibrating filter, dilutions, clarifier, centrifuge, vacuum dryer, storage tank, dispatch) conditioning right will optimize degradation of identified chemicals (esp., hemicellulose, cellulose), to retain property of oil, to enhance complete separation oil molecules from the degraded hydrophilic molecules. Made possible by mill incorporating; chemical catalysts or/and enzymes additives during the milling or oil extraction process. The current efficiency of the respective processing (ramp, conveyer, sterilizer, digester, press, vibrating filter, dilutions, clarifier, centrifuge, vacuum dryer, storage tank, dispatch) conditioning to maximize degradation of identified chemicals help separation oil molecules is low. Addition of chemical or biochemical catalyst that helps to degrade, esp., hemicellulose, cellulose to free more oil. Azis

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16 Sterilization is purely a chemical process We inject steam into the vessel containing FFB and after a period of time, fruits detach from the bunch and cells free from each other. The process produces.. glucose (6 carbon) and xylose (5 carbon) and Dr Azis

17 hemicellulose (short molecule) xylose OH glucose OH. for 10 tons FFB 100 o C. ~ 2 hrs for zero USB cellulose (short molecule) glucose xylose hemicellulose (long molecule) Energized H 2 O of palm bunch 120 o C 10 mins. steam OH cellulose (short molecule) OH OH disaccharide OH. for 10 tons FFB 120 o C. ~ 1 hrs for zero USB Loss of this water (H 2 O) through evaporation leads to hydrolytic deficiency glucose xylose disaccharide (sucrose) OH OH OH OH OH OH OH. for 10 tons FFB 140 o C. ~ 0.5hrs for zero USB hemicellulose (long molecule) H 2 O of palm bunch glucose xylose hemicellulose (long molecule) Dr Azis

18 Steam peeling of potato Steam peeling is carried out either as a batch-wise or a continuous process. Batch-wise the raw materials (roots, tubers) are treated in a pressure vessel and exposed to high-pressure steam (145psi or 10bars (180 C) 203psi or 14bars (200 C)). The high temperature causes a rapid heating and cooking of the surface layer (within s). The pressure is then instantly released, which causes flashing-off of the cooked skin. (http. 200psi steam Chips, crisps Azis

19 a n d a t t h e s a m e time prepare the b i o m a s s for the milling p r o c e s s to p r o d u c e g l u cose and xylose. Glucose and xyloses are consistently produced at every processing step in the mill. The amount produced depends on the sequential biomass and processing conditions (temperature, pressure and processing throughput). Azis

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22 Fresh loose fruits Cellulose 100% Hemicellulose 100% Glucose = 0% Xylose = 0% Continuous sterilization (CS) 14.5 psi (steam) 40 meter conveying Cellulose 100% Hemicellulose 80 90% Glucose = 5-10% Xylose = 1-3% Horizontal/vertical/tilting /spherical psi hr Cellulose 100% Hemicellulose 70-80% Glucose = 10 15% Xylose = 3 5% Roborest psi mins Cellulose 100% Hemicellulose 50-70% Glucose = >15% Xylose = >5% Press/filter Press/filter Press/filter Press/filter Filtrate Pressed crude Residue Pressed fiber Filtrate Pressed crude Residue Pressed fiber Filtrate Pressed crude Residue Pressed fiber Filtrate Pressed crude Residue Pressed fiber Percentage of oil in pressed fiber at the press station Azis

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24 The perception of milling Milling process is about extraction of oil Be changed to Milling process is the chemical breakdown of hemicellulose and physical breakdown of a-cellulose and oil is waste and a lot of waste. OR Milling process is the production of glucose, xylose, and the waste is oil Azis

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27 Extractive and purification steps Extractive and purification steps Sterilization Preparative step Highest sterilization steam pressure 40 to 45psi (~3 bars) for 1 to 1.5hrs. Chemical innovations Enzymes Chemical catalysts 0.5 to 0.75 % OER increment of 20% (W. Malaysia) USB.. Significant % Effluent lower BOD COD Sterilization Preparative step Highest sterilization steam pressure 50 to 70psi (~4 to 5 bars) for < 1hr. 21 to 22% OER from current 20% (W. Malaysia) USB.. 0% Chemical innovations Enzymes Chemical catalysts Effluent significantly lower BOD COD Azis

28 Re s o l v i n g t h e e f f l u e nt problem High glucose, xylose 100ml water = 0.5gm oil 1000ml ( 1 liter = 1 kg) = 5gm oil 1,000liter = 1 ton = 5000gm oil 30 ton water = 150,000gm = 150kg oil. * * Low BOD/COD effluent Components POME PPF (palm oil mill effluent) (palm pressed fiber) ph Cellulose Lignin Crude protein Crude fiber Moisture content Ash Nitrogen free extract Suspended solid High BOD/COD effluent * * Biochemical Oxygen Demand or Biological Oxygen Demand (BOD), is a measurement of the amount of dissolved oxygen (DO) that is used by aerobic microorganisms, in ppm or mg/l. Chemical oxygen demand (COD) is a measure of the capacity of water to consume oxygen during the decomposition of organic matter and the oxidation of inorganic chemicals, in ppm or mg/l. Azis

29 Thank you very much