SUSTAINABLE PELLETISATION OF BUAH ... - unimas ir

SUSTAINABLE PELLETISATION OF BUAH ENGKABANG OR SHOREA MACROPHYLLA BIOMASS WASTES AS

FUEL FOR RURAL SARAWAK

Deny Anak Nerei

Bachelor of Engineering with Honours (Chemical Engineering)

2013

UNIVERSM MALAYSIA SARAWAK

Grade:

Please tick Ob

Final Year Project Report Masters

PhD

DECLARATION OF ORIGINAL WORK

This declaration is made on the, 2Q, day of, May, 2013.

Student's Declaration:

F71 ý 0

I, __ DEIVY_ANAK_1VEEEI_ (27F1,

_DEPT. _ OF_CHEMIýAL. EIVQIIVEERINCý. AND_ ENERGY aLT51AINEW. ILI. T. Y.,. FAGULTX. Qf.. FN. CxINB. EJKI G.. hereby declare that the work entitled,

$LJSTAINAR ULLE $A TIQN...

__QF, __ J

.... E1Vjli ]B N... H... IýHQRKJ 1l Ali C1. 1:

. El. EI. QMA6S.. WASTEa. A6. EIJEL. k'Q RURAtiL. ý., SARAWAK,. is my original work. I have not copied from any other students' work or from any other sources except where due to reference or acknowledgement is made explicitly in the text, nor has any part been written for me by another person.

2Q. MAX 2Q. ß ]ýýIX ýNý1. NE

. (2337.6)

Date submitted Name of the student (Matric No. )

Supervieor'e Declaration:

I, hereby certifies that the work entitled,

PELLETI$ATIQN.. QF_. B IAH_ENýIiABANý_ 0

..: ýHQIM4. C ? QPHjZ, L,

_ BIQMAS WA, STE_S. A5. Fj1EL_FQP__PTJZAL. SAAYVAK was prepared by the above named student, and was submitted to the "FACULTY" as a partial fulfilment for the conferment of Pý1ýHELQP__QF. EIVGIIVEE INS WITH. HQNQjJ (rHEMICAL. EN INEE LING)., and the aforementioned work, to the best of my knowledge, is the said student's work.

Received for examination by: NAZEJI ADBlVL. jAHMA__N_

(Name of the supervisor)

Date: 2Q

, MAY 2013

1

I declare this Project/Thesis is classified as (Please tick (b):

Q CONFIDENTIAL (Contains confidential information under the Official Secret Act 1972)*

QRESTRICTED (Contains restricted information as specified by the organisation where research was done)*

©OPEN ACCESS

Validation of PrajectJ! 'hesie

I therefore duly affirmed with free consent and willingness declare that this said Project/Thesis shall be placed officially in the Centre for Academic Information Services with the abiding interest and rights as follows:

" This Project/Thesis is the sole legal property of Universiti Malaysia Sarawak (UNIMAS).

" The Centre for Academic Information Services has the lawful right to make copies for the purpose of academic and research only and not for other purpose.

" The Centre for Academic Information Services has the lawful right to digitalise the content for the Local Content Database.

" The Centre for Academic Information Services has the lawful right to make copies of the Project/Thesis for academic exchange between Higher Learning Institute.

" No dispute or any claim shall arise from the student itself neither third party on this Project/Thesis once it becomes the sole property of UNIMAS.

" This Project/Thesis or any material, data and information related to it shall not be distributed, published or disclosed to any party by the student except with UNIMAS permission.

Student's signature: ý' f ' Supervisor's signat

(20 MA 2013) Current Address:

L0T.. 231..: I: AMAN..

PFNRI5. H N. 9 N. 5. Q K[IGUINý,

_ýAýAWAK

Notes: * If the Project/Thesis is CONFIDENTIAL or RESTRICTED, please attach together as annexure a letter from the organisation with the period and reasons of confidentiality and restriction.

[The instrument is duly prepared by The Centre for Academic Information Services]

11

APPROVAL SHEET

This final year report which entitled "Sustainable Pelletisation of Buah Engkabang or Shorea Macrophylla Biomass Wastes as Fuel for Rural Sarawak" was prepared by Deny Anak Nerei (23376) as a partial fulfilment for the Degree of Bachelor of Chemical Engineering is hereby read and approved by:

MR. NAZER

J

Date

3

(Supervisor)

iii

SUSTAINABLE PELLETISATION OF BUAH ENGKABANG OR SHOREA MACROPHYLLA BIOMASS WASTES AS FUEL

FOR RURAL SARAWAK

DENY ANAK NEREI

Thesis is submitted to

Faculty of Engineering, Universiti Malaysia Sarawak In Partial Fulfilment of the Requirements

For the Degree of Bachelor of Engineering Chemical Engineering (With Honours)

2013

iv

Dedicated to my late grandpa and

to my beloved mom, grandma, and my family,

who always bestow me sustainable motivations, inspirations and encouragements

V

ACKNOWLEDGEMENT

The author would like to express his grateful appreciations to all individuals, parties and organizations that have contributed and cooperated throughout the completion of this thesis. Special thanks are dedicated to his supervisor, Mr. Nazeri bin Abdul Rahman for his willingness to share his knowledge and experiences as well as for his constant support towards the completion of this thesis. Last but not least, the authors would like to express his thankfulness to his beloved family members, all his friends especially Rosemina Anak Liboma, Darren Armand Griak Anak Dublin Griak, Hii Yik Ming and Muhammad Hafiz bin Johari, and the respondents for the survey study from Kpg.

Sg. Reboh, Batu Lintang, Sri Aman and Kpg. Bengoh, Padawan, Kuching who either directly or indirectly involving in giving their supports and motivations toward the completion of this thesis.

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ABSTRAK

Di seluruh dunia, tenaga alternatif telah dijadikan sebagai sumber yang menggantikan bahan api fosil untuk kepelbagaian fungsi tenaga. Biomass sebagai sumber tenaga boleh diperbaharui mempunyai potensi dalam penjanaan kuasa tenaga dan kadar pembebasan gas rumah hijau yang rendah. Kadar pembebasan gas rumah hijau yang rendah dapat mengurangkan kesan negatif kepada alam sekitar. Sebagai sebuah negara pertanian, Malaysia menghasilkan

r biomass dalam kuantiti yang banyak. Oleh itu, sisa biomass boleh digentelkan dengan menghasilkan gentelan sebagai bahan api. Gentelan adalah bahan api pepejal yang dihasilkan dengan memampatkan bahan biomass ke saiz silinder yang kecil di bawah tekanan yang tinggi. Maka, kajian ini dilakukan dengan tujuan menggentelkan sisa biomass shorea macrophylla sebagai sumber bahan api. Kajian turut dilakukan dengan mengkaji penanaman shorea macrophylla dan cara-cara pelupusan sisa biomass yang diamalkan oleh para petani. Ciri-ciri gentelan yang dihasilkan diuji dan dianalisa dari segi kemampatan muatan, kemampatan gentelan, jumlah debu, kandungan kelembapan, nilai kalori dan kandungan abu. Gentelan yang dihasilkan mempunyai potensi sebagai bahan api untuk tujuan pemanasan. Secara keseluruhan, gentelan yang dihasilkan mempunyai nilai kalori dan ketumpatan yang tinggi berbanding dengan jenis gentelan yang lain. Kandungan kelembapan gentelan yang dihasilkan juga rendah. Walaupun kemampatan muatan rendah dan kandungan debu dan abu gentelan tinggi daripada jenis gentelan yang lain, kualiti gentelan yang dihasilkan boleh ditingkatkan untuk tujuan komersial. Kesimpulannya, gentelan daripada sisa biomass shorea macrophylla berpotensi sebagai bahan api untuk pembakaran dan penjanaan jana kuasa tenaga.

Kata kunci: Penggentelan, shorea macrophylla, sisa biomass, tenaga biomass.

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ABSTRACT

An alternative energy has been globally introduced as the promising sources in substituting fossil fuels for the energy diversification. As the source of renewable energy, biomass is determined to have potential in generating power supply and promoting low greenhouse gases (GHG) emission. The lower emission of GHG could reduce the negative impact of such gases to the environment.

Malaysia as an agricultural country produces large amount of biomass waste annually. As such, the waste can be pelletised and use as fuel for heating or power generation purposes. Pellet is a solid fuel which is the compressed biomass material under high pressure into small cylindrical size. As such, this study main aim is to utilise shorea macrophylla cultivation wastes as raw material for pelletisation. Corresponding to the aim, a survey is conducted in order to investigate the cultivation of shorea macrophylla and the current disposal method practised by the farmers. In addition, the identified wastes are pelletised and the properties of the shorea macrophylla wastes pellet is tested and analysed especially in term of bulk density, pellet density, amount of fines, moisture content, calorific value and ash content. Overall, the produced pellets from shorea macrophylla biomass wastes have high calorific value and the pellets densities are comparable to European pellet standard and other types of pellets. The study also found that the moisture content of the produced pellets are lower in which have increased its calorific value. Although the bulk density is lower, and amount of fines and ash content are higher than other types of pellet, the quality of the produced pellets can still be improved for commercialisation. As such, it can be concluded that the produced pellets have the tendency to be utilised as fuel for not only heating purposes but for power generation as well.

Keywords: Biomass energy, biomass wastes, shorea macrophylla, pelletisation.

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TABLE OF CONTENTS

DECLARATION OF ORIGINAL WORK APPROVAL SHEET

TITLE PAGE DEDICATION

ACKNOWLEDGEMENT ABSTRAK

ABSTRACT

TABLE OF CONTENTS LIST OF TABLES

LIST OF FIGURES ABBREVIATIONS NOMENCLATURE

CHAPTER 1 INTRODUCTION 1.1 Biomass 1.2 Sustainability 1.3 Pelletisation

1.4 Shorea Macrophylla Species 1.5 Research Problem

1.6 Objectives and Scope of Study 1.7 Methodology

Pages i in

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V

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1 2 3 5 6 7 7

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1.8 Expected Outcomes 9

1.9 Summary 9

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 10

2.2 Energy Demand in Malaysia 10

2.3 Biomass Production 12

2.3.1 Biomass Wastes in Malaysia 15

2.3.2 Agricultural Residues in Malaysia 15 2.3.3 Palm Oil Mill Residues in Malaysia 17

2.4 Shorea Macrophylla Cultivation 20

2.5 Biomass Densification 24

2.6 Pelletisation 27

2.6.1 Pellet Production Technique 2.6.2 European Standards for Pellets 2.6.3 Biomass Pellets

2.6.4 Agricultural Pellets 2.6.5 Wood Pellets

2.7 Sustainability 2.8 Summary

28 29 30

33

35 36 38

CHAPTER3 METHODOLOGY

3.1 Introduction 40

3.2 Literature Review 40

3.3 Identification of Shorea Cultivation Waste 41

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3.3.1 Questionnaire 41

3.3.2 Site Location 42

3.3.3 Site Visit 42

3.3.4 Data Analysis 42

3.4 Pelletisation 42

3.4.1 Mould Preparation 42

3.4.2 Shorea Macrophylla Cultivation Waste 43 Preparation

3.4.3 Pelleting Process 44

3.5 Experimental Testing 3.5.1 Bulk Density 3.5.2 Pellet Density 3.5.3 Amount of Fines 3.5.4 Moisture Content 3.5.5 Calorific Value 3.5.6 Ash Content 3.6 Result and Discussion 3.7 Summary

CHAPTER 4 QUESTIONNAIRE 4.1 Introduction

4.2 Part 1: Personal Information

4.3 Part 2: Shorea Cultivation Information

46 47 47 47 48 49 51 52 52

53 53 53 4.4 Part 3: Shorea Processing Biomass Waste and 56

Disposal Method

4.5 Part 4: Additional Information 57

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4.6 Summary 57

CHAPTER 5 QUESTIONNAIRE DATA ANALYSIS

5.1 Introduction 59

5.1.1 Location of Study 59

5.1.2 Respondent Working Experience 62

5.2 Shorea Cultivation Survey 62

5.2.1 Shorea Cultivation Tree 64

5.2.1 Shorea Harvesting Method 64

5.2.3 Harvested Shorea Cultivation and Maturity 65 Period

5.2.4 Shorea Flowering and Ripening Period 65

5.2.5 Shorea Cultivation Purposes 69

5.3 Shorea Processing Biomass Waste and Disposal 70 Mode

5.4 Additional Information Survey 72

5.5 Summary 75

CHAPTER 6 EXPERIMENTAL ANALYSIS 6.1 Introduction

6.2 Pellet Characteristics 6.3 Bulk Density

6.4 Pellet Density 6.5 Amount of Fines 6.6 Moisture Content

77 77 78 79 83 85

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6.7 Calorific Value 6.8 Ash Content 6.9 Summary

CHAPTER 7 RESULT AND DISCUSSION 7.1 Introduction

7.2 Effect of Pellet Mould 7.3 The Overall Result 7.4 Effect of Bulk Density 7.5 Effect of Pellet Density 7.6 Effect of Amount of Fines 7.7 Effect of Moisture Content 7.8 Effect of Calorific Value 7.9 Effect of Ash Content 7.10 Summary

CHAPTER 8 CONCLUSIONS AND RECOMMENDATIONS 8.1 Introduction

8.2 Conclusions

8.3 Recommendations for Further Works 8.4 Summary

BIBLIOGRAPHY

APPENDIX A GANTT CHART APPENDIX B QUESTIONNAIRE

88 91 93

95 95 96 96 98 100 101 103 104 107

108 108 110 112 113 123 124

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LIST OF TABLES

Table Page

1.1 Taxonomy of Shorea Macrophylla 5

2.1 Amount of biomass generated in Malaysia in 2007 16 2.2 The density of biomass for certain densification technologies 25

2.3 Comparison between briquettes and pellets 26

2.4 The European pellets standards 31

2.5 Technical specifications of properties for pellets 32

2.6 The properties of typical biomass pellet 33

2.7 The properties of certain agricultural pellets 34

2.8 Calorific value of oil palm EFB and woody pellet 35

2.9 The properties of wood pellets and wood chips 36

2.10 Five aspects of sustainability criteria 38

5.1 The amount of shorea trees cultivated by the respondents 64 5.2 The quantities of shorea fruits harvested by the respondents 65 5.3 Biomass wastes disposal methods for shorea cultivation 71

5.4 Difficulties experienced in shorea cultivation 72

5.5 The labour force during the growing period 73

5.6 The labour force during the harvesting period 74

5.7 Sources of information regarding the pelletisation process 75

6.1 The average weight for unpelletised samples 78

6.2 The bulk density for unpelletised samples 80

6.3 The bulk density for 6mm pellets 80

6.4 The bulk density for 8mm pellets 81

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6.5 Comparison of average bulk density for all three types of 81 sample

6.6 The pellet density for 6mm pellets 82

6.7 The pellet density for 8mm pellets 82

6.8 Comparison of all three types of average pellet density 83

6.9 The amount of fines for 6mm pellets 84

6.10 The amount of fines for 8mm pellets 84

6.11 Comparison of average amount of fines for 6mm and 8mm 85 pellets

6.12 The moisture content for unpelletised samples 86

6.13 The moisture content for 6mm pellets 86

6.14 The moisture content for 8mm pellets 87

6.15 Comparison of average moisture content for all three types of 88 sample

6.16 The calorific value for unpelletised samples 89

6.17 The calorific value for 6mm pellets 89

6.18 The calorific value for 8mm pellets 90

6.19 Comparison of average calorific value for all three types of 90 sample

6.20 The ash content for 6mm pellets 92

6.21 The ash content for 8mm pellets 92

6.22 Comparison of average ash content for 6mm and 8mm pellets 93

7.1 The result for unpelletised samples 96

7.2 The result for 6mm pellet size 96

7.3 The result for 8mm pellet size 96

7.4 Comparison of shorea macrophylla wastes pellet bulk density 97

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to other pellets

7.5 Comparison of shorea macrophylla wastes pellet density to 99 other pellets

7.6 Comparison of shorea macrophylla wastes pellet amount of 101 fines to other pellets

7.7 Comparison of shorea macrophylla wastes pellet moisture 102 content to other pellets

7.8 Comparison of shorea macrophylla wastes pellet calorific value 104 to other pellets

7.9 Comparison of shorea macrophylla wastes pellet ash content to 106 other pellets

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LIST OF FIGURES

Figure Page

1.1 The scope of biomass initiatives as renewable energy 2 1.2 An overview process of biomass densification 4

1.3 Shorea Macrophylla Fruit 6

2.1 The total energy demand in Malaysia from 2000 to 2030 11 2.2 The trend of energy mix in Malaysia from 1978 to 2013 12

2.3 The thermo-chemical conversion of biomass 13

2.4 The Van Krevelen diagram for a mixture of solid fuels 14

2.5 Paddy and rice production 17

2.6 Contribution of oil production in the world in 2007 18 2.7 A reddish brown winged fruits of shorea macrophylla tree 21 2.8 The parallel layout of rubber and chorea macrophylla 22

(meranti) plantation

2.9 The simultaneous form of layout of rubber and chorea 22 macrophylla (meranti) plantation

2.10 A schematic diagram of pelletisation process 28

2.11 The flat type die block 29

2.12 The ring die block 29

2.13 The wood pellets generated from saw dust 35

3.1 The process flow of the study 40

3.2 The three-dimension of male and female mould 43 3.3 (a) The dimension of holes on female mould; (b) The 44

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dimension of male mould

3.4 The flow chart of raw material preparation 45

3.5 Hydraulic floor jack in a rig 45

3.6 The process flow of pellets production 46

3.7 Moisture analyser 49

3.8 An automated bomb calorimeter 51

4.1 Questions on the respondent's personal information 54 4.2(i) Questions on shorea cultivation information 54 4.2(ü) Questions on shorea cultivation information 55 4.2(äi) Questions on shorea cultivation information 56 4.3(i) Questions on wastes generated and disposal method 56 4.3(ü) Questions on wastes generated and disposal method 57 4.4 Question on additional cultivation information 58 5.1 The location of survey for both site visits 60 5.2 The interviewed session with the respondents at Kpg. Sg. 60

Reboh; (a) In Undop Longhouse; (b) In Ijok Longhouse

5.3 The occupation of the respondents at Kampung Sg. Reboh 61 5.4 The interviewed session at Kpg. Bengoh; (a) Interviewed with 61

the chief village (respondent); (b) Interviewed with a very experienced respondent

5.5 The occupation of the respondents at Kpg. Bengoh 61 5.6 The working experience of the respondents from both site 62

visits

5.7 The purpose of cultivation 64

5.8 The flowering period of shorea at both site visits 66 5.9 The ripening period of shorea at both site visits 67

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5.10 The fruiting period of shorea at both site visits 68 5.11 The fruiting cycle of shorea at both site visits 68 5.12 The cultivation of shorea trees at both site visits 69

5.13 The reason of cultivating shorea trees 70

5.14 The purposes of cutting shorea trees 71

5.15 The respondents' knowledge on pelletisation of shorea wastes 74 6.1 6mm pellet samples; (a) 100% Fruits; (b) 100% Peels; (c) 100% 78

Petals

6.2 8mm pellet samples; (a) 100% Fruits; (b) 100% Peels; (c) 100% 79 Petals

6.3 The average bulk density graph of unpelletised samples, 6mm 81 and 8mm pellets

6.4 The graph of 6mm and 8mm average pellet density 83 6.5 The graph of amount of fines for 6mm and 8mm pellets 85 6.6 The average moisture content graph of unpelletised samples, 88

6mm and 8mm pellets

6.7 The calorific value graph of unpelletised samples, 6mm and 91 8mm pellets

6.8 The graph of ash content for 6mm and 8mm pellets 93

7.1 Comparison of pellet bulk density graph 98

7.2 Comparison of pellet density graph 99

7.3 Comparison of amount of fines pellet graph 101

7.4 Comparison of pellet moisture content graph 103

7.5 Comparison of pellet calorific value graph 105

7.6 Comparison of pellet ash content graph 106

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ABBREVIATIONS

APEC Asia Pacific Economic Cooperation

ASAE American Society of Agricultural Engineers Standard ASEAN Associated of South East Asian Nation

CBE Cocoa Butter Equivalent CHP Combine Heat and Power CPW Citrus Pectin Waste Pellets

EC European Commission

EFB Empty Fruit Bunches

EUBIA European Biomass Industry Association

GHG Greenhouse Gas

MARDI Malaysian Agricultural Research and Development Institute KPE Palm Kernel Expeller

PHAs Polyhydroxyalkanoates PLA Polylactate

POME Palm Oil Mill Effluent RCG Reed Canary Grass Pellets RM Ringgit Malaysia

SFH Sun Flower Husk Pellets

WCED World Commission on Environmental Development

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NOMENCLATURE

% Percentage

°C Degree Celcius

Peulk Bulk Density Peelet Pellet Density

A Amount of ash

CO2 Carbon Dioxide

cm Centimeter

EJ Exajoules

EJ/yr Exajoules per year

F Amount of Fines

GWh Gigawatthour

GJ/m3 Gigajoules per volume GJ/t Gigajoules per tonne

ha Hectare

kg/m3 Kilogramme per volume kg/cm2 Kilogramme per area ktoe Kilo tonne of oil equivalent ktonnes Kilo tonnes

kWh Kilowatt hour

kWh/kg Kilowatt hour per kilogramme kWh/m3 Kilowatt hour per volume lb/ft3 Pound per volume

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MC Moisture Content

MF Mass of Fines

MJ/kg Megajoules per kilogramme MJ/m3 Megajoules per volume

Ms Mass of Sample

Mtoe Million tonnes of oil equivalent

m Meter

mg/kg Milligram per kilogramme

mm Milimeter

m3/ tonne Volume per tonne

Qc Combustion Heat

Qcc Heat Measure of Complete Combustion QM Heat Measured Value

rpm Revolution Per Minute VBulk Bulk Volume

VPellet Pellet Volume

WA Weight of Ash

Wary Dry Weight

WWet Wet Weight

W; Initial Weight

WBulk Bulk Weight WPellet Pellet Weight wt% Weight Percent

yr Year

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CHAPTER 1

INTRODUCTION

1.1 Biomass

Biomass is scientifically identified as biological material originated from living organism due to its organic matrix and heterogeneous nature (Lorenzini et al., 2010; Biomass Energy Centre, 2012). It is an abundant source of renewable energy which has the essential elements of carbon, hydrogen and oxygen therefore it can be partially utilised in substituting fossil fuels (Abnisa et al., 2011). Kassim (2011) classified biomass as woody and non-woody in which forest residues, agriculture residues, bush trees and farm trees are categorised as woody biomass while plant stems, bagasse, straw, leaves, nutshells, husk, sewage and sawdust are classified as non-woody biomass which derives from crop residues. According to Koh and Hoi (2003), biomass is found to be resourceful as it can be produced in three forms in which, biogas is an example of gaseous form, alcohol represents liquid form, and charcoal and briquettes as solid form.

In Malaysia, biomass energy is primarily derived from agricultural based wastes especially those from oil palm waste as such empty fruit bunches (EFB), mesocarp fibers, trunks and fronds, paddy residues such as husk and straw, and wood wastes. Ali et al. (2012) stated that the contribution of biomass fuel is also estimated to be 16% of the total energy consumption in Malaysia in which 51%

of this value is from palm oil wastes, 27% from wood wastes and 2% from paddy

1