Retrofit of Palm Oil Complexes

as an Integrated Biorefinery

JEREMIAH F. OGUGO
H84DEV PROJECT
YOUSRA BAGHDADI
 Presentation outline
 Introduction

 Objectives

 Palm Oil Mill Process Description

 Methodology

A Case Study of Palm Oil Mill

Superstructure Approach
Mathematical Optimization
 Result and Analysis

 Conclusion

H84DEV PROJECT 1
 Introduction
 Palm fruit is also known as Elaeis Guineensis.
 Originated in the tropical rain forest region of west Africa.
 Oil Palm fruit processing has been practiced in Africa for ages on small-
scale for edible oil.
 Malaysia is currently the world second largest producer and exporter of palm
oil.
 At the palm oil mill, 1 ton of FFB contains about 20% palm oil, 6–7% palm
kernel, 11-12% fiber, 6–7% shell, 60% POME and 23% EFB.
 The biomass generated can be used as source of fuel to generate steam and
electricity to fulfill the plant energy requirements.
 Generation of palm oil mill waste could be valuable by using it in biorefinery
to produce Biodiesel, Methanol and other valued products.

H84DEV PROJECT 2
 Objectives
 Retrofit of palm oil mill complexes as an integrated biorefinery.

 Development of mathematical optimization model to retrofit

palm oil mill as an integrated biorefinery.
 Mathematical analysis was applied as to ascertain the
technologies that give high yield by optimization
 Selected Pathways by the model that give optimal solution and
products for maximum profit would be involved for an
integrated biorefinery

H84DEV PROJECT 3
 Palm Oil Process Description Diagram

H84DEV PROJECT 4
 Methodology
Case Study of Palm Oil Mill
 A case study of 30 tonnes/h of FFB was considered to obtain the different amount of
products and biomass generated from each of the processes involved.
 The Material Balances of a Case Study Palm Oil Mill
EFFLUENT =34147 kg/h
FFB = 30000 kg/h

FFB
THRESHING EFB = 7171 kg/h

Steam = 7500 kg/h 26976 Kg /h

STERILIZATION FIBER =14.3%
H2 O=24 kg/h CPO =11.3%
SHELL = 13%
WW = 3377 kg/h POME = 61.45%
30876 kg
DIGESTER
FIBER =13.6%
CPO =14.37% Steam = 3900 kg/h
Steam = 3300 kg/
SHELL = 13%
h POME = 59.03%
SOLID OUTLET FIBER = 3600 kg/h
15105 kg
PULP PRESSING FIBER CYCLONE
FIBER =26.4%
LIQUID OUTLET SHELL = 15%
19071 kg POME = 58.6% 11505 kg/h
CPO =15.56% SHELL = 23%
POME = 84.44% POME = 77%

CLARIFICATION NUT CRACKER

POME CPO KERNEL POME SHELL

12771 kg/h 6300 kg/h 1609 kg/h 7577 kg/h 2121 kg/h

H84DEV PROJECT 5
 Methodology
Case Study of Palm Oil Mill
WW
WW=0.536/CPO
FFB = 4.762/CPO
EFB=1.138/CPO EFB

Power = 0.004 PPF= 0.571/CPO

KWh/Kg CPO PPF

PKS= 0.337/CPO

KERNEL=0.287/CPO PK
Steam = 2.333/CPO S

CPO= 1 KERNEL

Water= 0.004/CPO POME=3.229/CPO

CPO

POME
H84 DEV
H84DEV PROJECT
PROJECT 6
 Superstructure Approach
 A superstructure approach was used to built a model that would run an integrated biorefinery
 Many conversion technologies, Primary products, Upgrading techn., Intermediate Products,
Energy Conversion and End products.

CONVERSION PRIMARY UPGRADING INTERMEDIAT ENERGY END

BIOMASS
TECHNOLOGY PRODUCTS TECHNOLOGY E PRODUCTS CONVERSION PRODUCTS

K11 Boiler L11 Steam N11

K1 Steam Electricity
J11 L1 Turbine
Direct M1 M11 P1
N1 N12
Combustion K21
J12
F11 J1
Bio-char Methanol N21 Heat
SHELL K2 L22 M22 Engine P2
Synthesis Methanol N22
F1 F12 N2
L2 M2
F13 Gasification K32 M23
J23
J2 Syngas K33 Catalytic Methanol
K3 P3
J26 J32 Conversion N3
F21 L35 H2 N33
F22 J33 L3 M3 M34
K34
FIBER Methane
J34
F2 F23 Pyrolysis K4 Water Gas Shift H2
J3 K35 L43
M42 P4
L4 N4 N44
F32 J35 Biofuel
Bio-Oil (Gasoline )
K5 L54 M45 Biofuel
F31 J44 Fisher Tropsch M4 (Gasoline )
F33
Anaerobic L5 M52 N5 P5
EFB N55
Digestion J46
F3 CO2 K56 Ethanol
J4
F34 K6 L63 M5
Catalytic M56
Ethanol
Cracking P6
K57 N6 N66
Briquette L6 M62
F44 J5
J57 K7 Biodiesel
POME M6
F4 Transesterification L76 Biodiesel
M67
F46 L7 N7 P7
K8 N77
J68 K88
Fermentation L85
L8 M78
J6 M7
J69
N88 Acid
K9 K99 L97 N8
L9 P8

H84DEV PROJECT
 Mathematical Optimization
 The optimization models consist of objective functions are
formed from the source-sink material balance, unit operation
material balance, technical specification and process
modeling.
 A software-LINGO was used to solve the model to
maximum profit from the integrated biorefinery.
 Information from the literature about conversions ,
operating conditions, and prices of the products were used.
 The built model was allow to select reasonable and
productive pathway for the whole process and other
individual product.

H84DEV PROJECT 8
 Maximum Profit Equation
Results and Analysis
MP= Products Price + Electricity Profit- [Purchase Elect + Purchase Steam]

BIOMASS
CONVERSION PRIMARY UPGRADING
Methanol
INTERMEDIAT ENERGY END
TECHNOLOGY PRODUCTS TECHNOLOGY E PRODUCTS
Synthesis 22
CONVERSION PRODUCTS
Methanol
SHELL K1
K11 Boiler L11 L2
Steam
Steam M2N11 Electricity
Turbine M23
F1 Direct
J11 L1 M1 M11 N1
P1
F13 Combustion
N12
F11 J1 J12 K21 Methanol
Bio-char N21 Heat
Methanol
Engine N3 P3
SHELL K2 Synthesis L22 Methanol M22
N2 N22
P2 N33
F1 F12 M2
L2
F13 Gasification K32 Methane M23
J23
FIBER J2 Syngas K33 K4Catalytic Methanol
K3
F2 F23 Pyrolysis
J26 J32 Conversion N3 P3
H2 N33
F21
F22 J3 J33 L3
L35
M34
FIBER
J35
Methane
K34Bio-Oil M3
J34
F2 F23 Pyrolysis K4
K35
K5 Gas Shift
Water M42
H2
J3 L4 L43 N4 P4
F32 N44
J35 Biofuel
F33 J44
Bio-Oil (Gasoline )
EFBF31 Anaerobic
J44
K5 L54
M4
M45 Biofuel
Fisher Tropsch (Gasoline )
F3 F33
Anaerobic Digestion L5 N5 P5
EFB M52
F3
Digestion J4
J46 CO2
N55
J4 K56 Ethanol
F34 K6 L63 M5
Catalytic K57 M56
Ethanol
Cracking P6
K57 N6 N66
L6
F44
F44 J5
Briquette M62 Biodiesel
J57 K7
POME
Biodiesel
Transesterification M6
Transesterification M6 L76 Biodiesel
M67 Biodiesel
POME
F4
L7
L76 L7 M67
N7 P7 N7 P7
F4 F46
J68
K8 N77 N77
K88 L85
Fermentation

Solve the model for Maximum Profit (MP)

L8 M78
J6 M7
J69
N88 Acid
K9 K99 L97 N8
L9 P8
Objective value: 990046.4
Total solver iterations: 15
Variable Value Reduced Cost
MP 990046.4 0.000000
P3 1601.988 0.000000
P7 631.6002 0.000000
H84DEV PROJECT 9
 Results and Analysis
Electricity
P1

SHELL N21
F1 Engine
F12
Gasification N2
J2 J23
Syngas
K3 Catalytic
Conversion
F22
L3
FIBER L35
F2

F32

EFB
F3 M52
Ethanol
M5

Maximize the Electricity

Global optimal solution found.
Objective value: 9812.754
Total solver iterations: 19
Variable Value Reduced Cost
P1 9812.754 0.000000
MP 499.1653 0.000000

H84DEV PROJECT 10
 Results and Analysis
K11 Boiler L11 Steam
Steam Turbine
J11 K1 L1 M1 M11
Direct N1 N12
Combustion
F11 J1 Heat
SHELL Engine P2
F1 N22
N2
F13

F21

FIBER
F2 Pyrolysis
J3
J35 Bio-Oil
F31 K5

EFB
M52
F3 Ethanol
M5
K57

POME Biodiesel
F4 Transesterification M6 Biodiesel
L76 M67
L7 N7 P7
K8 N77
Fermentation K88
J6 L8

Maximize the Heat

Global optimal solution found.
Objective value: 13297.11
Total solver iterations: 21
Variable Value Reduced Cost
P2 13297.11 0.000000
F1 3597.300 0.000000
F11 3597.221 0.000000
P7 0.3875170E-02 0.000000
H84DEV PROJECT MP 0.000000 0.7461148E-02 11
 Results and Analysis
Methanol
Synthesis 22 Methanol
L2 M2
SHELL K32 M23
F12 Gasification
F1 J23
J2 Syngas
K3 K42 Methanol
N3 P3
F22 N33
Methane
K4
FIBER
F2

F32 J44

EFB Anaerobic
F3 Digestion
J4

Maximize the Methanol

F44 Global optimal solution found.
POME Objective value: 2649.284
F4
Total solver iterations: 11
Variable Value Reduced Cost
P3 2649.284 0.000000
MP 944467.1 0.000000

H84DEV PROJECT 12
 Results and Analysis
SHELL
F12 Gasification
F1 J23
J2 Syngas
K3
F22
K34
H2
M3 M34
FIBER
H2
F2
Water Gas Shift P4
L4 L43 N4 N44
F32

EFB Anaerobic
F3 Digestion
J46
J4 CO2
K6

F44

POME
F4
Maximize the Hydrogen
Global optimal solution found.
Objective value: 2304.052
Total solver iterations: 11
Variable Value Reduced Cost
P4 2304.052 0.000000
K6 7526.799 0.000000
MP 8038.570 0.000000

H84DEV PROJECT 13
 Results and Analysis
SHELL
F12 Gasification
F1 J23
J2 Syngas
K3
F22

FIBER
F2
K35
F32 Biofuel
L54 (Gasoline)
Biofuel
Fisher Tropsch M4 M45
(Gasoline)
L5 P5
EFB Anaerobic N5
F3 Digestion N55
J4 J46 CO2
K6

F44

POME
F4
Maximize the Gasoline
Global optimal solution found.
Objective value: 921.6207
Total solver iterations: 9
Variable Value Reduced Cost
P5 921.6207 0.000000
K6 7526.799 0.000000
MP 65616.82 0.000000

H84DEV PROJECT 14
SHELL
Results and Analysis
F12 Gasification
F1 J23
J2 Syngas
K3 K33 Catalytic
F22 Conversion
L3
FIBER
F2

F32

EFB
F3 Ethanol
M56
M5 Ethanol
N6 N66 P6

POME
F4 L85
F46
K8
Fermentation K88
J6 L8

Maximize the Ethanol

Global optimal solution found.
Objective value: 6132.971
Total solver iterations: 11
Variable Value Reduced Cost
P6 6132.971 0.000000
MP 307872.6 0.000000

H84DEV PROJECT 15
SHELL
F1
Results and Analysis
F13

FIBER
F2 F23 Pyrolysis
J3
J35
Bio-Oil
K5
F33
EFB Anaerobic
F3 Digestion
J4 J46 CO2
K6
K57

F44 Biodiesel
Transesterification M6
POME L76 Biodiesel
F4 L7 M67 P7
N7 N77

Maximize the Biodiesel

Global optimal solution found.
Objective value: 631.6002
Total solver iterations: 5
Variable Value Reduced Cost
P7 631.6002 0.000000
K6 7526.799 0.000000
MP 418937.8 0.000000

H84DEV PROJECT 16
 Result and Analysis Boiler 11 Steam
Steam
Turbine
L1 M1 N1 N12
K21
Bio-char Heat
K2 P2
SHELL
F1
F13
J32

FIBER
F2 F23 Pyrolysis
J3

EFB
F3

J5 Briquette
J57 K7
POME
F4 F46
Fermentation M7 M78
J6 K99 N88
J69 K9 L97 N8 Acid
L9 P8

Maximize the Acid

Global optimal solution found.
Objective value: 10171.35
Total solver iterations: 5
Variable Value Reduced Cost

P8 10171.35 0.000000
K7 7169.400 0.000000
H84DEV PROJECT P2 138.7197 0.000000 17
 Results and Analysis
Maximize Product Product yield(kg) Maximum Profit ($)

All end products Methanol=1601.988 990046.4

Biodiesel=631.6

Electricity Electricity=9812.75 449.17

Heat Heat=13297 0.0000

Methanol Methanol=2649.28 944467

Hydrogen CO2=7526.8 8038.57

Hydrogen=2304.05 90.32

Biofuel CO2=7526.8 90.32

Biofuel=921.62 65616.82

Ethanol Ethanol=6132.97 307872.6

Biodiesel CO2=7526.8 90.32

Biodiesel=631.6 418937.8

Acetic Acid Briquette=716904 103951.08

Acetic acid=10171.35 4371.1
Heat=138.72

H84DEV PROJECT 18
 Conclusions
 To integrate a biorefinery to a palm oil mill of this
capacity, pathways of all the products is favored.
 Methanol and Biodiesel pathways of the model were
quite promising and should be considered.
 Product Price is a major decision factor on the
pathway of the model to integrate in to the biorefinery.
For maximum production of methanol and biodiesel,
gasification, pyrolysis and anaerobic digestion are the
favourable biomass conversion technologies.

H84DEV PROJECT 19
Thank You