Journey Started-Joint Research Collaboration ( Jan 2004-Dec 2006) FPI-UPM-KIT of Japan

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Toby Harper
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Study on potential downstream of palm biomass project -bio-compost, bio-ethanol,

The studies developed skills and know-how in regards to palm biomass related project.

2 Journey Started-Joint Research Collaboration ( Jan 2004-Dec 2006) FPI-UPM-KIT of Japan - Scopes of R&D i. Study on biogas production from POME Anaerobic treatment ii. Study on potential downstream of palm biomass project -bio-compost, bio-ethanol, bioplastics. The studies developed skills and know-how in regards to palm biomass related project. 500mt Biogas Pilot Plant Serting Hilir Mill Designed by Sumitomo Heavy Industries Pty. Ltd. Constructed by Workshop Division of FELDA Palm Industries Sdn. Bhd.

4 Palm Oil Mill Effluent, POME POME : FFB ratio : 1.0 Contains very high amount of organic matter Typical characteristic COD 50,000-70,000 mg/l BOD 25,000-30,000 mg/l ph Temp o C O&G, SS & other trace elements Mill efficiency and EFB disposal option to determine the characteristics

in a year) Electricity Generation 4 0 4 Boiler gas burner 2 2.

5 Summary Of The Biogas Projects Status Project Implementation FPI Equity BOOT Project Total Completed In Progress In the Pipeline ( ) mills (5-6 projects in a year) Electricity Generation Boiler gas burner 2 2. Electricity generation for grid connected and supplementary fuel in the boiler Further exploration- Compressed Bio-methane, CBM

6 Besout Maokil Kemahang 6

7 Serting Hilir 7

8 Optimization of Anaerobic Operations POME pre-treatment Feeding pattern- Continuous/intermittent feeding Reduce loading shock Increase bacteria/sludge retention time, SRT.

BIOGAS Production: 20-35 m 3 /mt POME Composition: Methane : 55-65% Carbon dioxide: 35-45% Hydrogen sulphide: 1,500 3,000 vppm RAW POME -54 MT FFB POME: 700-900 m 3 /day BOD: 25,000 35,000 mg/l COD:

9 BIOGAS Production: m 3 /mt POME Composition: Methane : 55-65% Carbon dioxide: 35-45% Hydrogen sulphide: 1,500 3,000 vppm RAW POME -54 MT FFB POME: m 3 /day BOD: 25,000 35,000 mg/l COD: 50,000 70,000 mg/l Loading: kg COD/m 3.d SLUDGE RETURN DIGESTED POME Flow: m 3 /day BOD: <1,000 mg/l (total) COD: 8,000 12,000 mg/l (total) ANAEROBIC DIGESTER Typical performance of POME anaerobic digestion

10 BIOGAS PROJECT FOR RURAL ELECTRIFICATION GENERATION AT KS UMAS, TAWAU, SABAH.

11 Background of the project Commissioned :Biogas October 2011 :Engine December 2012 Gas Engine Installed Capacity (1 unit) : 1.2MWe Electricity supply to the Felda Engineering Services Sdn Bhd (FESSB) at about MWe for the distribution to Felda Umas s Settlement area ( 5km away). Sharing electricity load with existing diesel gensetsaving of diesel. New pond (45,000m3 capacity) vs retrofitting existing pond

12 Economic analysis Umas Mill Biogas Power Generation Plant Items Cost (RM million) Construction of Pond Covered Anaerobic Digester 4.6 Downstream gas processing set up, 800m3/hr 2.6 Gas 1200 kw capacity 2.0 Cabling for 5kms, transformers and related facilities 2.8 Electricity RM0.45/kWh x 5.76 million kwh/yr Payback period years

13 Basis operational parameters-biogas Plant Commercial Biogas Production Unit Items Potential electricity 1 m3 biogas ( 65% methane) Potential biogas production Basis 2kwh 25-35m3/ mt POME Methane composition in biogas 50-60% H2S content before scrubbing Expected H2S content after scrubbing pm < 300ppm

14 The project-construction stage

15 - Construction stage

16 Biogas Plant Anaerobic Covered Pond

17 800m3/hr- Bioscrubber system.

18 Gas Engine control room Set-up Transformer 415v/11kv 1.2 MWe Containerized Gas Engine Containerized Gas Engine 1.2 Mwe & Control Room Building.

19 Supply to FES diesel genset station, ( 2x500kw + 800kw) for distribution to FELDA Umas settlement area, 5km away. Normal operation, elecicity from gas engine + 1 unit diesel genset Containerized Guascor Gas Engine 1.2 Mwe. Normal electricity generation, kwh

20 1. Electric power generation from renewable fuel vs fossil fuel Saving from electricity generation cost (RM /kwh) vs RM /kwh Internal usage to replace diesel genset Continuous effort in promoting smaller carbon footprint in milling process. 2. Continuous power supply for aeration in tertiary treatment plant to remove remaining BOD Increase POME treatment efficiency Reduce land requirement

21 Other Future Potential Project Proposal Production of Compressed Biogas (CBG) for Industrial application (boiler system) Upgrading of biogas to produce CBG for Vehicle fueling

22 Challenges And Barriers Environmental concern in wastewater treatment process - Continuous improvement on standard discharge compliance New technologies that needs skills and knowledge of staffs with high competencies. Supporting the 3P s pillars of sustainability- people, profit and planet.

23 TOWARDS SUSTAINABLE PALM MILLING -Majulah biogas untuk SEMUA 23

FELDA PALM INDUSTRIES SDN. BHD

FELDA PALM INDUSTRIES SDN. BHD Development of Biogas Projects in Felda Global Ventures Reflections & Way Forward and Opportunities for Value Creation in Palm Oil Based Biogas Biogas Asia Pacific Forum