Fact Sheet: Alternative fuel and raw material (AFR) review “Coconut shells” 1 Classification according to European Waste Catalogue EWC \Wostes from agriculture, horticulture, aquaculture, forestry, hunting and fishin, food preparation and processing ‘Wace from fruit. vegetables, cereals. edible ols cocoa. coffe. tea and 0203 tobacco preparation and procestng, conserve production, yeast and yeast extract production, molasses preparation and fermentation 020304 Materials uneuitable fr consumption or processing 2 1.1 AFRdescription ‘ripe coconut hata hardshell covered bya fibrous outer cat Inside, theres an edible eemel with the cocanut inthe middle, Once the nut is broken the kernel can be dred Ln the moisture contents below 6% in order to prevent deterioration. Ths dried meat is called copra and s then subject to pressing or extraction for ol after which coconut (oil mea! (or cake), copra meal or poonac is left over [F1] ‘The remainder consists of broken coconut shes the sizes of which are roughly upto ‘around 202m, The mesocarp of coconuts consists of brownish flres.1.2. AFRpictures gure 62 AFRsource and composition 21 Source Once the coconuts are harvested the husks are removed and the nutsare cut open to ‘obtain the white meat [6-2]. Then the coconuts are dried in order to preduce copra and the ollis obtained from the copra by expression or other prepress solvent extraction ‘methods [P21 Large quantities of husk ae especially easy to collectin places where coconut meatis traditionally used in food processing [A] ‘The relative amounts of the compounds of an average coconut areas follows: ono > Wen i205 S158 2.2 Quantity and availability ao See ee (ee‘oble 25 displays coconut producti testimates of coconut shell arsings are prov {2 coconut consists of shell Region Country Benin Cameroon Capeverde Comoros congo Ce divore Equatorial ‘Guinea Ghana Guinea Guinea Bissau Ken trea beta Madagascar aurtius Mozambique Nigeria saoTome and Principe Senesal | Seychelles SiewaLeone Somalia Tose Tonzania 2005, coconutss COCA (tonnes) (tonnes) zpe 3000 6658 999 6,00 300 soa 13623 3,000 450 216332421 7828 nama 31500047250 pes 4219 45500 6825 63000 9450 7000 1050 24500 12675 2375 356 440900 66,000, 20900031350 2os7 3089, 4700 705 2500 a5 3,000 450 rasa 2123 vaso 2,175 45933968901 17200 5000 5300 83,200 3350 249,200 7300 237,900 39000 40,100 nes 6300 81900 900 277900 170900 25400 5,100 1700 2900 15600 13400 590.000 jon at country level 2005 and 2010, Aditional, idod based on the assumption that 15% of shall (tonnes) 2380 750 195 13230 503 37380 1.085 oss 3850 6015 10896 945 12285 285 4168s. 25500 3960 765, 255 435 2010Cees [ternative fuel an raw material (AFR) review Coconut shells" Bangladesh Brunel Darustalam cambodia China India Indonesia Malaysia aldves yanmar Nepal Pakistan Philippines Singapore sritanka Thalia Timor-Leste Vietnam Peize Costa Rica Salvador Guatemala Honduras Guyana Peru Venezuela 5,000 358 7900 271036 8829.00 18250,000 S700 16420 42q085 354 8367 14824500 197 isiis10 11910.330 9000 977.200 1262 25,000 54007 3879 15996 1.166:00 6000 14353 3.118940 10797 20350 356 7313 Bas8 548 146926 13350 * 10650 40655 11324350 2737,500 85650 263 64207 33 1255 222300 ™ 256742 201050 1380 146580 180 3900 8101 93582 2398 175920 900 2153 67881 16,189 3,083 10547 3a73 m 22039 370 56 75800 11460 308650046250 10824100 1623615 20655400 3,098,310, 5276227943 320 6 35030052545 354 33 8900 1335, 15540000 2331000 70 26 2238800 335820 7aa150 198773, 3700 1305 179900 176.985, 670 101 8000 1200 65800 10320 2230 3345, 14100215 983000 147.450 7500 125 14900 2100 2705860 405879 8200012300 211003165 310 a nao 10710 25654 3.998, 3709 1306 vag100 28215, onindon spe 131> comind epee aa ee 200s 2010 ce || Se cma || Sine! comes ei tenes) Gorm coe perc er ee as ; (Ee, mos tron as a a ee = a pms 3D Eee re zen ake conn conto et ee ee selorensguo kaon an40ow0 oe nn aes | ‘or sam ==«8700==« 73000 | vooas — soopon a5 tmo Bow 2380 are ee) ae | eae is ‘ommes Gouce Grand 57,193,883 8,579,082 62,008,276 9,301,241 Considering the numbers of husk and shell percentages displayed in figure 17 the | ‘otential arising of fibres and shells suitable for alternative fuel can be estimated. Based Petthe 2010 figures and taking into account that coconuts provide around 15% shells Sry as 39s husks [6-1], the globally avaliable amounts are approximately 9:3 milion tonnes of shells and 207 milion tonnes of husk. Coconuts are @ permanent crop and available throughout the whole year (8-1) ‘Therefore, there [sno specific harvesting season and supply of coconuts fs possible continuously.ermative fuel and raw material (AFR) 2.3 Flow chart of AFR production Sheting Remedi eying Raw material tage Ceaningrnspection Scorching Presing | Op Coprameatcake ou 1 2.4 AFR composition ‘The coconut fruit isa fibrous deupe with a smooth outer skin (called exocarp) that va- Jes from green to red brown or even ivory [S-1lA young coconuts skin (called meso- ‘atp) shite and fe while ripe coconut consist of fibrous mass and the husk from which coiris obtained (5-1. \nithin the fibrous mass thee isthe nut with a hard shell (called endocarp) enclosing tne kernel (called endosperm [5-1]. [5-1] describes further that between the shell and the kemelis the testa, a thin brown seed coat which adheres frm tothe kernel, an approx ‘mately 12mm thick ning that covers the central cavity containing the nut water hence ‘the sloshing sound of water inside when a mature coconuts shaken. Inthe end, the vo lume of water in amature coconut diminishes due to absorption by the endosperm Us- se or because of evaporation (5-1) Coconut shellsare composed mainly of ignin, cellulose and pentosans a component of hemicellulose They havea chemical composition ver similar to weod (1). But accoré- {ng to 6-1 they have higher lignin content than cellulose and ae also sed as Fertilisers because of thei potassium content. awe 18:07 Amcor igews 133‘The following table gives an overview ofthe composition of coconut shell on dry bass ma une ‘aloe Cehioe ‘san asi 626 Ugnn xan est Eamt canas Xn ai 2.5 AFRanalysis Uimate aswell as proximate analysis of coconut hells ae shown nthe following table coconut Coconut ccm Sormt, pate “al, cowmauinis uot sharom MARLO amply tamale PhIPINeS unknown) unknown) Feferencestte rymaver—deymater wa asc Mote ome 92105 bss * os os as W RO an ROS MRT eral vai oie eee 8 Me c Mose ae i | FI me argo EIN PSE 4 | ° sem a os Mn N Rel eases whe aes oman 5 om me a. NOSE a 5 LE ne aon igpenenig yg 204605 cc ung oust aout 9 source ca eT te “erred Fro NEV MM cane om to cy AY2.6 AFRash composition ‘An example of the chemical ash composition of coconut shells is displayed inthe next table: Compound Unit Value Ko % 4501 Nao * 152 20 * 626 Ngo * 132 Fe0,+A10, * 139 P.0, * 464 $0, * 575 50, * 464 Coconut shell shes feature large amounts of alkalis, predominantly potassium. 3 Harmful substances and hazardous characteristics From thelr origin, coconut shells do not contain harmful substances. However, it «depends on further handing whether disruptive materials unrelated to coconut waste enter by accident or deliberately, the load of coconut shells which s hauled tothe nal destination (cement plan). Indeed, with copra expeller or mea thee i ask of asphyalation and polsoning when Inaled while entering a storage hall or containers [7-1], Access should not be permed tothe storage areas until the ar has been sufficiently ventlated and tested with agas detector, points out. Ascoconut Mle ishighty onygen-absorbing,a life-threatening shortage of oxygen may ais inside a losed storage hall or container [2 Therefore, before entering fresh at needs tobe introduced, ventilated and, if necessary, 2 g2s measurement cared out (72 Coconut floes very susceptible to self-heating, especially when moisture is being absorbed. Bales compressed in an excessively moist condition are at risk of heating ‘uring extended transportation routes and storage, wit the result being decay rather than spontaneous combustion [1-2 \wnile shredding coconut shells dust generation is probable Workers should use er Sonal protection equipment (PPE) such asa dust mask. Tobe 2:04 Collection, recycling and disposal of the AFR 4.1, Collection and transport Large quantities of coconut shells are especially ey to collect in places where coconut meat is used traditionally in food processing (ATL. They can be collected in big bags or Containers or direct in covered and wind: protected areas atthe production site. Trans- portation is performed by using regular lores, Coconut cot ibres) must be protected from moisture asitis strongly hygroscopic and {eadly absorbs moisture. Therefor, before transpert the loading area should be cov- ‘red to avoid loss of material by wind F airstream and to avoid becoming wet during Fainfall Copra expeller is mostly ansported as bulk ands only rarely bagged [1-1] “The dry blk density of eaconut shells is around 40skg/m?[K-1] to 435k [C2 Ie needs to be noted that copra expeller and coconut husk are classified under the HAZ MAT flammable solids class 42 and therefore special attention should be given during the storage and transportation due to their combustible nature [-1] Especially smok Ing/open flames should be prohibited throughout the loading discharge and access toholds (11 42 Recycling, current use and disposal Copra cake (according to[P-1)): opracakeisaby-product of coconut oil extraction The de-husked coconutis spt open tnd the meat is scraped aut and dried. Oil extraction from the dried copra takes place ‘is expeller or solvent processes. Copra cakeis available throughout the whole year and Ir therefore a cheap local source of anima feed, The cake s ground to meal for poultry, cattle, sheep, and swine feeding, Coconut shells: Coconut shells ae used, for example, in South India and Sri Lanka without pretreat tment as fuel in villages and also by local industries such as laundries, bakeries and iron foundries (P11, Coconut shells are one of the raw materials for charcoal production. The shel charcoals manufactured using burning shells of wholy ripe nuts in ited ar atmosphere suita- Ble only fr carborisation, but nt for compete destruction (C-1] Moreover rom coco put shell charcoal activated carbon is manufactured [C1] itis advised touse only the coconut shllsas fuel. asthe other components can be recy cled and reused Coir: Coir Isa valuable and flexible fibre thats derive from the coconut husk. Coir pith Is ‘waste product obtained during the extraction of coir fibre from husk. is ery light, ‘igh compressible and highly hygrascop The best cor i produced from green coco puts But these are more difficult to harvest and havea lower copra return than mature ‘coconuts“These fibres are used in many countries inthe automotive industry as insulation mate tialand upholstering material for example seats). Baskets for lowers or other mats (such ‘for mattresses, geotaxtles) are also produced from col In South America fox exam ple, Dalmler Benz iitiated a fist project forthe use of such fibres about 10 yeats ago. In some countries, coi i alo processed into a sol conditioner (as altemative for peat). Usually, larger coconut processing facies sel the fibres finding their way into appl- Cations as described, thus depriving coi of being used as uel It is used asa soll cond ‘ones, surface mulch/oting medium and desiccant. Composted coir pith i excellent ‘organic manure fr indoor plants as wel a for horticulture crops 4,3. Useas alternative fuel in a cement or lime plant Coconut shes have been usedin the cementindustry asa renewable energy source for many years Being vitally dry with only modest moisture content, combined with sat isfactory calorie value, coconut shell afford good substitution potent ‘Owing to low ash content coconut shells present themselves. quite useable as fuelin lime rotary kins, once downsized to appropriate grain sizes. 4.3.1 Economic value of the AFR in a cement or lime plant Calorific value Compared to typically employed coal or petcoke, the potential substitution factor for sing coconut shells are dsplayed in the following table: Fuel substitution calculation CClorifievalue Substitution factor Substitution factor ‘hale ‘CV coal ‘CV petcoke Coconut shells 4400 138 1.86 Coal 6,100 1 = Petcoke 5200 = 1 Basedon typical calorific values of solid foi fuels. in conjunction withan average value ‘of 4400kcalrkg of coconut shells, one tonne of coal or petcoke can be substituted by atound 138 to 1.86 tonnes of coconut shells. Biomass-CO,-value Being natural material, coconut shells afford iterally 100% renewable energy source ‘Once combusted, the earbon dioxide released is considered as neutral with regard to ‘greenhouse gas emissions. The extent ofthe potential reduction of fossderived carbon dioxide by using coconut sells can be appraised through a simple approach Coal has an emission factor of 96kg CO, per G! [+2] which fs equivalent to 245 tonnes CO, per tonne of coal with 6,100 kcal/kg). By using 1.38t coconut shells according to ‘able 29 instead of one tonne of coal, the emission of 2.45 of fosi-derved carbon cix- Ide can be entirely prevented. Table 23! soace MW)However forthe implementation of COM projects, the complete supply chal ie CO; aot during coeonut collection bain, transportation, processing, has tobe taken into consideration. 43.2. AFR pre-processing “Some cement plants use coconut shellsas they are. This means tat the shells ae nto erealinte the kiln inlet via'a double flap valve The feeding of coconuts in this way i+ Soften accompanied by the feeding of whoke tyres. For more challenging feeding points, e. the combustion chamber, coconut shells Fee be downsized to roughly Sornm. Downsizing an be achieved by e. single shaft aponicens equipped with square blades and a basket screen having the respective sizes, aaa edna break quite easly, a simple crusher (eg. Jaw crusher, single or double ae cots) can be used to crush cocondt shells into small pieces. AS jaw crushers are ‘ually not equipped with a screen basket, subsequent screening to the desired grain see Pefoner oF even kin burner feeding is indicated. For example, the indian com- Baty tecpro Systems manufactures small low-cost crushers igh} sutableto downsize Eocon shells (see next pictur). ree 20 nly minimum technical equipment is requted: A front loader for feeding coconuts Miele shredder, the shredder itself and an upward inclined conveyor belt for heaping sree ed matersL Nevertheless, staf in charge ofthe operation should alwayskeep an ) Srrout for probable csruptive part inthe feedstock in order to segregate that mate oor out ot tued it into the crusher, Even smaller gan sizes can be produced easly, 35 ‘oconut shells are e25y tocrush.43.3 Storage at the plant site Coconut shells at customers Taclities ae pften stored in heaps outside any bul fing. The picture on the right shows an ‘Daample of separated storage compart nents for coconuts beside compart- Tents for whole tyes and rice husk storing of coconut shells exposed tothe ‘Clements does however have some dis ‘Sdvantages. Although coconut shells themselves are not prone to absor> excessively rain water ~ which deter States the calorific value ~ water may femain in the bowi-like shape of the {hes and might enter the kiln on Feed ing, thus provoking increased eneray “consumption and fue gas volume. Being hygroscopic, adherent coir might also increase the moisture content. In order to prevent deleterious inf fences from water, combustibles should, ‘sarule, be stored weatherproot 4.3.4 Dosing and feeding systems ‘As already previously mentioned, coco fa shells can be fed into the kin ile. Coconut shells are conveyed by means inclined carveyor belts from storege to the preheater tower. Metering can be Schieved by a weighing belt whichis. placed either nea tothe feeding hop- per next to the storage or just Behind fhe bi inthe preheater. This depends fon the individually available space. In the preheater tower, a small bin collects the material The outlet ofthe bins con- tected toa vibrating chute which con veysthe shellstoa double lp valve. The {double fap valve is connected to the fiser duct jst above the kiln let. Aso this feeding pints often fed with rte, ‘Alco manval handling can be observed. Big bags are filled with coconut shells, The Big sag Iifted manvally tothe respective stage ofthe preheater tower nore 0600 bags ae Ips manually into 9 chute ofthe double lap valve stands to reason that ‘though practiced -thiskind of feeding isnot state ofthe >.‘Coconut shells downsized tog. less than 50 70mm canbe fedntothecaciner which ray be a combustion chamber. Once conveyed by indined ribbed belt conveyors to the preheater tower, the caconut chips can be fed gravimetically bya screw weigh feeder Into the cental channel af the combustion chamber burner. ‘once ground to smaller grain sizes, gles than 10mm, the material can be fed directly bby pneumatic feeding ystems int the kiln burner. 4.3.5 Quality influence on clinker and lime “The influences onthe clinker and lime quality are generally assumed tobe negligible ‘owing to the very low ash content The ash content of coconut shel is foughly 1 = 2%, far less than typical coal and within the range of petcake. However, coconut ashes {are rch in potassium which might give sein particular in conjunction with chlorine {rom other alternative fuels to increased kiln salt circulation and formation of ings or ‘coatings 5 Recommendations "= Wastes from coconut farms can be used as environmentaly-tiendly alterna ‘ive fuel.Sourced directly from smaller plantations, the use of coconut shells in ‘the cement and lime industry can offer an extra income tothe farmers. Coco- rut reyeling projects, involving material reuse, 9, bre reuse as mats copra 3s petfood, shells as fuel are candidates forthe generation of new jobs. These projects reduce the negative environmental impact of large-scale mono plan- tations In most counties coconut projects qualfy 35 COM projects. Coconut shells can be used in cement aswell asin lime plants. tis advised to secure coconut shells 3s fuel resource wellin advance, depend ing onthe fosi fuel prices. Coconut ashes have a low ash content which rch in potassium. Especially in ‘onjunction vith chlorine this may promate the formation of ings or coatings. Weather protected storages advisable in order to avoid water being fd into the kiln thus provoking increased energy consumption and flue gas volume. 6 References [)_ 0.0. Amu, 0.5, Owokade, ©. Shitan Potentials of Caconut Shell and Husk Ash ‘on the Geotechnical Properties of Lateitic Soil for Road Works. International ‘ournal a Engineering and Technology, Vol3/No. 2, 2011, pp.87 = 94. [BA]. J,A.Banzon:The Coconut as Renewable Energy Source. Philippine Journal of Caconut Studies, une 1980. [82] 0.0, Gamalan: Processing Manual for Vigin Coconut Ol its Products and 8y- products for Pacific Island Counties and Territories. Secretarat ofthe Pacific Community, New Caledonia, 2011,[C1] COB Coconut Development Board: Processing Technology. Available at htto// coconutboard.nicin/charcoathtm (checked in September 2011) [C2] LE Cruz: Producer-gas Technology for Rural Application. FAO Agricultural er- vices Bulletin, Ne. 61, Rome (aly), 1985, p.7. IFT] FAO: Cocos Nuctera. Availabe at http:/Avwwfa0.0rg/ag/aGa/agap/FAG/ats/ Data/498.HTM (checked in Jly 2012) IF-2} FAO Statistics: Coconut Production, Avalable at: tp aostatfao.rg/site/291/ default asp (checked in July 2012, [G1 8. Grimwood, F Ashman, E-C. 5 Little, D.A.V. Dendy, C. Jarman, W.H-Thm- ‘mins: Coconut Palm Products: Their Processing in Developing Counties. Food and Agricultural Organization ofthe United Nations, Rome italy), 1975, pp. 147 ay I-11 10: Small-scale Oil Extraction from Groundnuts and Copra. Technology and Employment Branch; UNIDO, Geneva (Switzerland), Vienna (Austria), 1983, [121 {PCC Intergovernmental Panel on Climate Change: Revised 1996 IPCC Gulte- lines for National Greenhouse Gas Inventories, Vol.3: Reference Manual. 1995. K-11 Kuhe, €. 1. Kucha, H. A lortyer: Experimental investigation of Biomass Gas- ication ina Closed Top Troatless Downdraft Gasifier International Journal of Advanced Renewable Energy Research, Vol. 1, 2012, sue 6, pp. 307 ~ 312, [P-1]_ M.D. Pickard By-product Utilisation, Bile’ Edible Ol and Fat Products: Prod- tuts and Applications, Volume 4 2005, pp. 380-416, IP 31 .G.Punchinewa, PLN. Arancon: Coconut Poot harvest Operations APCC Aan and Paciic Coconut Community, Jakarta indonesia), October 1999, [5-1] GA Santos, PA. Batugal, A. Othman, L. Boudouin, J.P Labouisse: Manual on Standardized Research Techniques in Coconut Breeding, Chapter 1: Botany of the Coconut Palm. Available at: http://www? bioversityinternational.or/pab lcationsveb_version/ 108/ch02 htmeChapters6201%4208OTANYS5200F%26 ‘THE%s20COCONUT3Z0PALM (checked in July 2012) 1-1] _Tansportnformations-Service 5) des Gesamtverbandes der Deutschen Ves- ‘cherungs Wieschaft eV. (GOV): Copre Expele.Avallable at hetpi/vawrt-ed, deitis_elware/ftterlexpeller/kopra/kopra.htm (checked in July 2012) [72] _Transportinformations-Service (TiS) des Gesamtverbandes der Deutschen Ver sicherungs-nirschaf eV. (GOV: Coconut Fibre. Avaliable at http:/wnwutis-cd. ets. e/ware/fasern/kokosfa/kokosfahtm (checkedin July 2012. [73] _A.J.Tsamba: Fundamental Study of Two Selected Topical Biomass for Enewy: ‘Coconut and Cashew Nut Shells Thess KTH School of Industrial Engineering and ‘Management {TT}, Materials Science and Engineering, Energy and Furnace Tech- nology, Stockholm (Sweden), 2008, [U-1] United Nations Conference on Trade and Development 2012: Infocomm —Com- ‘modity Profile Coconut, Avalable at httpd/mww.unctad:nforen/infocomm/ ‘AACP-Products/COMMODITY-PROFILE-Cocont2/ (checked in July 2012)