Solid Fuel From Empty Fruit Bunch Fiber And Recycled Material.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
SOLID FUEL FROM EMPTY FRUIT BUNCH FIBER AND
RECYCLED MATERIAL
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Materials) with Honors.
By
NIKMAH BINTI ABD MUIN
FACULTY OF MANUFACTURING ENGINEERING
2010
DECLARATION
I hereby, declared this report entitled “Solid Fuel from Empty Fruit Bunch and
Recycled Material” is the results of my own research except as cited in references.
Signature
:
……………………………….
Author’s Name
:
NIKMAH BINTI ABD MUIN
Date
:
18th May 2010
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Engineering Materials) with Honors. The member of the supervisory
committee is as follow:
………………..………………………
(Principal Supervisor)
(MOHD YUHAZRI BIN YAAKOB)
ABSTRACT
This research purpose is to study and analyze the effect of different ratio from the
mixture of Empty Fruit Bunch Fiber (EFB) and recycled material briquettes towards the
combustion properties. This research also aims to utilize the abundant materials such as
palm biomass and waste papers into a useful product to minimize the quantity of wastes
produced in this country. The main raw materials used in this study are EFB fiber and
waste papers. Basically, these two materials were mixed up and turned into solid fuel
briquettes by briquetting technology. The mixtures were compacted into a solid briquette
using a hydraulic compression machine. The typical pressure applied to compress the
briquette is 12 000 lb. After that, the briquettes have undergone two types of testing
which is chemical testing and mechanical testing. All the testing conducted were referred
according to the standard test methods provided by ASTM standard. Types of chemical
testing tested onto the fuel briquettes are moisture content test, ash content test,
combustion test, gas emission test and combustion analysis. As for the mechanical
testing, types of testing that have been conducted are crack test, stability test, water
resistance test, durability test and compression test. From the testing, the best ratio of the
biomass briquettes were observed and selected. From the analyses of both chemical and
mechanical testing, it was found that sample briquette with ratio 60:40 has given a
highest value of heat released which is 162.77 kJ, whereas sample with ratio 40:60 has
good burning time, and better compressive strength. Meanwhile, sample ratio of 50:50
has produced lowest ash content and sample ratio 90:10 has given the lowest gas
emission of carbon, nitrogen and sulfur and the best sample that sustained its
dimensional stability.
i
ABSTRAK
Kajian ini dijalankan adalah bertujuan untuk mengkaji dan menganalisa kesan tenaga
pembakaran yang berlaku terhadap campuran dua bahan mentah iaitu Empty Fruit Bunch
(EFB) dan bahan yang boleh dikitar semula pada kadar nisbah yang berbeza – beza.
Kajian ini juga turut dihasilkan dengan matlamat untuk menggunakan bahan – bahan
terbuang seperti hasil buangan kelapa sawit dan bahan terbuang pada tahap yang
optimum bagi mengurangkan kuantiti bahan terbuang yang dihasilkan dalam negara
pada setiap tahun. Bahan utama yang akan terlibat dalam projek ini ialah EFB dan kertas
terbuang. Secara keseluruhannya, EFB dan kertas terbuang tersebut akan dihancurkan
dan dicampurkan menjadi satu adunan bagi menghasilkan sampel berbentuk pepejal
yang dikenali sebagai “briquette”. Hasil campuran tersebut akan dimampatkan ke dalam
bentuk pepejal menggunakan mesin mampatan pada tekanan 12 000 lb. Selepas pepejal
briquette berjaya dibentuk, ia akan melalui dua jenis ujian iaitu ujian kimia dan ujian
mekanikal. Ujian kimia yang akan dilakukan adalah seperti ujian kelembapan, ujian
isipadu abu yang dihasilkan selepas pembakaran,ujian pembakaran, ujian pembebasan
gas dan ujian analisa pembakaran. Manakala ujian mekanikal yang terlibat adalah seperti
ujian keretakan, ujian kestabilan, ujian ketahanan, uijan ketahanan pada air, dan akhir
sekali ujian mampatan. Berdasarkan ujian – ujian tersebut, nisbah 60:40 telah memberi
nilai haba pembebasan yang paling tinggi iaitu sebanyak 162.77 kJ, manakala nisbah
40:60 telah memberikan masa pembakaran yang paling lama dan nilai kekuatan tekanan
yg paling baik. Sementara itu, nisbah 50:50 telah menunjukkan nilai abu yg paling
rendah selepas pembakaran dah nisbah 90:10 merekodkan nilai pembebasan gas paling
rendah disamping mampu mengekalkan kestabilannya dengan baik.
ii
DEDICATION
For my beloved family especially my parents Abd Muin B. Ahmad and
Kalthom Binti Hasan and friends
iii
ACKNOWLEDGEMENT
I would like to convey my thanks to the all person who had contributed in ensuring a
successful occurrence throughout the duration of my final year project. I also gratefully
acknowledge to my PSM supervisor, Encik Yuhazri Bin Yaakob, for his encouragement,
fully support, by providing me enormous guidance and idea for my research project.
Without them all, this project may not valuable. Their knowledge and experience has
fully inspired, motivated and drive me to complete my final year project successfully.
Also, my special thanks to
all my peers, especially Siti Faizah, Nur Rifhan, Nurfarizan and Nurhashima, and to
those who are undergoing final year in Degree programs, thanks for your all kindness of
delivering ideas and motivation that necessary for me to complete this study. Besides
those mentioned, I also would like to express my gratitude with highly appreciation and
dedication to my family because without them, I won’t be here to complete my study in
Universiti Teknikal Malaysia, Melaka.
iv
TABLE OF CONTENTS
TOPICS
CHAPTER
1
2
PAGES
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Contents
v
List of Tables
ix
List of Figures
xi
List of Symbols
xiv
List of Abbreviations
xv
INTRODUCTION
1
1.1
Background of Study
1
1.2
Problem Statements
3
1.3
Objectives
4
1.4
Scope of Study
4
1.5
Thesis Frame
4
LITERATURE REVIEW
6
2.1
Biomass
6
2.1.1
Biomass Energy Potential
7
2.1.2
Availability of Biomass in Malaysia
8
2.2
Oil Palm
10
2.2.1
11
Oil Palm Biomass and Energy Content
v
2.2.2
2.3
Empty Fruit Bunch
13
Solid Fuel via Briquetting Technology
14
2.3.1
15
Fuel Briquettes
2.3.1.1 Production of Fuel Briquettes
From Waste Paper and Coconut
Husk Admixtures
2.3.2
16
2.3.1.2 Summary of Journal
17
Briquetting Process
18
2.3.2.1 Production of Palm Based
Biomass Briquettes
2.3.2.2 Summary of Journal
2.4
20
Municipal Solid Waste
21
2.4.1
Solid Waste Generation in Malaysia
21
2.4.2
Fiber Energy Recovery: Use of
Wastepaper as Fuel
3
18
24
2.5
Binder System
24
2.6
Chemical Properties Analysis
25
2.7
Mechanical Properties Analysis
27
2.8
Summary of Literature View
30
METHODOLOGY
31
3.1
Introduction
31
3.2
Materials
33
3.2.1 Empty Fruit Bunch
33
3.2.2 Recycled Paper
34
Sample Preparation
34
3.3.1 Raw Material Preparation
35
3.3
3.3.1.1 Drying
35
3.3.1.2 Blending
36
3.3.2 Sample Fabrication
3.3.2.1 Blending Ratios
vi
37
39
3.3.2.2 Addition of Binder
3.4
Laboratory Testing
41
3.4.1
Chemical Testing
42
3.4.1.1 Combustion Test
42
3.4.1.2 Ash Content
43
3.4.1.3 Moisture Content
43
3.4.1.4 Gas Emission
43
3.4.1.5 Combustion Analysis
44
Mechanical Testing
45
3.4.2.1 Compression Test
45
3.4.2.2 Water Resistance Test
46
3.4.2.3 Stability Test
47
3.4.2.4 Crack Test
47
3.4.2
4
40
RESULTS & DISCUSSIONS
48
4.1
Specimen
48
4.2
Experimental Work
50
4.3
Result of Chemical Properties Analyses
54
4.3.1
Combustion Testing
54
4.3.1.1 Combustion Test for S/N 1
55
4.3.1.2 Combustion Test for S/N 2
56
4.3.1.3 Combustion Test for S/N 3
57
4.3.1.4 Combustion Test for S/N 4
58
4.3.1.5 Combustion Test for S/N 5
59
4.3.1.6 Combustion Test for S/N 6
60
4.3.1.7 Comparison on Overall Briquettes
61
4.4
Results of Mechanical Testing Analyses
73
4.2.1
Compression Test
73
4.2.1.1 Compression Test for S/N 1
75
4.2.1.2 Compression Test for S/N 2
76
4.2.1.3 Compression Test for S/N 3
77
vii
5
4.2.1.4 Compression Test for S/N 4
77
4.2.1.5 Compression Test for S/N 5
78
4.2.1.6 Compression Test for S/N 6
79
4.2.1.7 Comparison on Overall Briquettes
80
4.2.2
Stability Test
84
4.2.3
Crack Test
87
4.2.4
Immerse Test
89
CONCLUSION & RECOMMENDATION
90
5.1
Conclusion
90
5.2
Recommendation
91
REFERENCES
92
APPENDICES
A
Gantt chart of PSM I
B
Gantt chart of PSM II
C
Compression test results
viii
LIST OF TABLES
NO.
TITLE
PAGES
1.1
Palm Biomass generated in year 2005
2
2.1
Oil Palm planted areas and FFB production in 2005
9
2.2
Oil Palm Biomass Energy Potential
9
2.3
Heat value of Oil Palm Biomass (KCAL/Kg, dry)
12
2.4
Energy database for Palm Biomass
12
2.5
Different shapes of fuel briquettes
15
2.6
Solid waste composition locations in Peninsular Malaysia
22
2.7
MSW generated in Kuala Lumpur in 2002
23
2.8
Kuala Lumpur’s solid composition (1975 – 2000)
23
2.9
Properties of the raw materials and Palm based biomass briquettes 26
2.10
Analysis results of the olive refuse and paper mill waste samples
26
2.11
Briquettes moisture content
27
2.12
Equilibrium moisture content and density of the briquette
28
2.13
Durability rating of the briquettes
29
2.14
Dimensional changes in briquettes after 3-day immersion in water 30
3.2
Properties of EFB as raw materials
3.3
Sample identification of EFB and recycled paper by weight percent 39
3.4
Sample identification of solid briquette by weight of binder
40
4.1
Sample ratio and its serial number
49
4.2
Enthalpy of various element
62
4.3
Heat released for each sample briquettes
63
4.4
Ash content and percentage of ash for sample briquettes
66
4.5
Comparison of ash content
69
4.6
Amount of gas emission in sample briquettes
70
ix
33
4.7
Maximum load, compressive strength and modulus of sample
80
4.8
Stability of fuel briquettes
84
4.9
Percentage of water absorption of fuel briquettes
89
4.10
Dimensional changes of briquettes after 24 hours immersed
90
x
LIST OF FIGURES
NO.
TITLE
PAGES
2.1
Types of Biomass in Malaysia
9
2.2
Cross section of an oil palm fruit.
10
2.3
Oil palm trees in Malaysia
11
2.4
Palm Biomass
11
2.5
(a) An empty fruit bunch (EFB) and (b) it fibrous form
14
2.6
Samples briquettes produced with 100 % wastepaper
16
2.7
Samples of wastepaper-coconut husk briquettes
17
2.8
Palm based biomass briquetting process
19
2.9
(a) EFB Powder, (b) EFB Fibre and (c) Sawdust.
20
2.10
(a) EFB Briquette (b) EFB Powder + Sawdust (50:50)
(c) EFB Powder + Sawdust (40:60)
2.11
20
Solid waste composition of selected locations in Peninsular
Malaysia
22
3.1
Methodology Process Flow Chart
32
3.2
EFB fibrous form
33
3.3
(a) Paper Shredder Machine and (b) Shredded Paper
34
3.4
Process flow of raw material Preparation
35
3.5
Drying Oven
36
3.6
EFB Powder.
36
3.7
Cylindrical with a hollow shape of the fuel briquette
37
3.8
Hydraulic Press Machine
38
3.9
Fabrication process of solid fuel briquette
38
3.10
Digital Weighing Machine
39
3.11
Addition of starch in the mixture as binding agent
40
3.12
Types of testing on sample briquette
41
3.13
Gasifier for combustion test
42
xi
3.14
Gas particle analyzer
44
3.15
Burning Profile of Oil Palm Briquettes
44
3.16
Universal Testing Machine
45
3.17
Position of sample briquette on test machine
46
3.18
Set up for crack test
47
4.1
Solid briquette
49
4.2
Sample briquettes produced in different ratios
50
4.3
Method of preparing blending waste paper
51
4.4
Method of mixing the EFB with waste paper
52
4.5
Method of briquetting sample briquette
53
4.6
Method of ejecting compacted briquette
53
4.7
Graph of temperature vs. time for S/N 1
55
4.8
Graph of temperature vs. time for S/N 2
56
4.9
Graph of temperature vs. time for S/N 3
57
4.10
Graph of temperature vs. time for S/N 4
58
4.11
Graph of temperature vs. time for S/N 5
59
4.12
Graph of temperature vs. time for S/N 6
60
4.13
Graph of comparison on overall sample briquette
61
4.14
Comparison of heat released of sample briquettes
64
4.15
Percentage of ash in briquettes
67
4.16
Comparison in percentage of ash with journal
68
4.17
Comparison of sample S/N 5 with journal
69
4.18
Percentage of Oxygen and carbon dioxide in briquettes
71
4.19
Comparison of gas emission of solid briquettes
73
4.20
Position of sample briquette in lateral
74
4.21
Compression test of sample briquette
74
4.22
Sample briquette after compressed
75
4.23
Graph of compressive load for S/N 1
75
4.24
Compression graph for S/N 2
76
4.25
Compression graph for S/N 3
77
4.26
Compression graph for S/N 4
77
xii
4.27
Compression graph for S/N 5
78
4.28
Compression graph for S/N 6
79
4.29
Comparison of compressive load on samples
80
4.30
Histogram of compressive strength on overall briquettes
81
4.31
Comparison of sample briquettes with other journal
83
4.32
Stability test on fuel briquette
84
4.33
Bar graph on stability result of briquettes
85
4.34
Crack test results
88
4.35
Water immerse test result
90
xiii
LIST OF SYMBOL
°C
-
Celcius
e.m.c
-
electromagnetic compatibility
g/min
-
gram per minute
GPa
-
giga pascal
kJ/kg
-
Kilo Joule per kilogram
kN
-
Kilo Newton
kW
-
kilo watt
MPa
-
mega pascal
m
-
micro meter
mm
-
millimeter
N/m2
-
Newton per meter
%
-
Percentage
lb
-
Pound
S/N
-
Serial Number
w.t %
-
Weight Percent
xiv
LIST OF ABBREVIATION
BBQ
-
Barbeque
CPO
-
Crude Palm Oil
C
-
Carbon
CO2
-
Carbon Dioxide
CV
-
Calorific Value
EFB
-
Empty Fruit Bunch
EPSM
-
Environment Protection Society Malaysia
FEFB
-
Fiber Empty Fruit Bunch
FFB
-
Fresh Fruit Bunch
GCV
-
Gross Calorific value
H
-
Hydrogen
HHV
-
High Heating Value
KL
-
Kuala Lumpur
LHV
-
Lower Heating Value
N
-
Nitrogen
NOx
-
Nitrogen Monoxide
MPOB
-
Malaysian Palm Oil Board
MSW
-
Municipal Solid Waste
NCV
-
Net Calorific Value
PEFB
-
Pulverized Empty Fruit Bunch
PORIM
-
International Palm Oil Congress
RM
-
Ringgit Malaysia
SOx
-
Sulphur Monoxide
UN
-
United Nation
UV
-
Ultra Violet
WRI
-
Water Resistance Index
WTE
-
Waste – to – energy
xv
CHAPTER 1
INTRODUCTION
1.1
Background of study
Malaysian palm oil industry has grown tremendously over the last 4 decades, and
since then it has maintained its position as the leading world’s country in the
production of palm oil (Nasrin, A.B., et al., 2008). The Malaysian Palm Oil industry
recorded a mixed performance in 2005 due to continue in strong growth in
production. The oil palm is the prolific producer of biomass. Oil constitutes only
about 10 percent of the palm production while the rest is biomass (Yusof, B., and
Weng, C.K., 2004). The prices and export earnings dipped, despite an increase in
exports of all oil palm products during the year. The total oil palm planted area
increased by 4.5 percent or 174,000 hectares to 4.0 million hectares in year 2005.
Sabah remained the largest oil palm planted state with 1.2 million hectares or 30 %
of the total planted area (Basri, W., 2006). Since the oil crisis in 1970’s the use of
biomass as a source of energy is a topic of growing interest and debate (Ma, A.N.,
and Yusuf, B., 2005). Nevertheless, the industry has also generated a vast amount of
palm biomass, mainly from milling and crushing palm kernel. The types and amounts
of these biomass generated in year 2005 are tabulated in Table 1.1 (Nasrin, A.B., et
al., 2008). The oil consists of only a minor fraction of the total biomass produced in
the plantation. The remainder consists of huge amount of lignocelluloses materials in
the forms of fronds, trunk and empty fruit bunch (EFB). EFB is the main solid waste
obtained from milling process. However, due to its poor characteristic, it has
limitation to be used as fuel.
1
Table 1.1: Palm Biomass generated in year 2005. (Nasrin, A.B., et al., 2008)
Producing energy from renewable biomass is only one of the various ways of
responding to the challenges of the energy crisis. In 2004, Malaysia had about 3.87
million hectares of land under oil palm cultivation. Currently, more than 80 % of the
oil palm produced is used for food applications like cooking oil, frying oil and many
others. Oil palm is a perennial crop. It has an economic life span of about 25 years.
Traditionally, oil palm is grown for its oil example like palm oil, palm kernel oil, and
palm kernel cake as the community products. Besides palm oil and palm kernel, oil
palm industry generates large quantity of biomass residue which is side products as
stated before like fronds, trunks, EFB, palm oil mill effluent, palm fibre and shell that
have not been fully commercially exploited. Through concerted research and
development efforts by many research organizations including Malaysian Oil Palm
Board (MPOB), this co – products from palm oil industry have been found to be
good resources for many application. There are many competitive uses of these
materials. One of them is to utilize them as a fuel for energy production. In fact,
Malaysian government has identified biomass as fifth fuel resource to compliment
the petroleum, gas, coal, and hydro as energy resources. Palm biomass has been
identified as a single most important energy source. On the other hands, the main
sources of biomass in Malaysia are domestic wastes, agricultural wastes, effluent
sludge and wood chips.
Biomass energy systems can be based on a wide range of feedstock. They use many
different conversion technologies to produce solid, liquid, and gaseous fuels. These
can then be used to provide heat, electricity and fuels to power vehicles; using
burners, boilers, generators, internal combustion engines, turbine or fuel cells. Power
can be generated by co – firing a small portion of biomass on existing power plant,
2
burning biomass in conventional steam boilers, biomass gasification and anaerobic
digestion (PORIM International Palm Oil Congress, 1996).
Converting palm biomass into a uniform and solid fuel through briquetting process
appears to be an attractive solution in upgrading its properties and add value. (Nasrin,
A.B., et al., 2008). Biomass briquette is the process of converting low bulk density
biomass into high density and energy concentrated fuel briquettes. Biomass briquette
plant is of various sizes which converts biomass into a solid fuel. Briquettes are ready
substitute of coal or wood in industrial boiler and brick kiln for thermal application.
Biomass briquettes are non conventional source of energy, renewable in nature, eco –
friendly, non polluting and economical. Process of converting biomass into solid fuel
is non polluting process. It involves drying, cutting, grinding, and pressing with or
without the aid of a binder.
1.2
Problem statement
Malaysia has involved in palm oil industry over the last four decades and since then
it has generated vast quantities of palm biomass, mainly from milling and crushing
palm kernel. Empty fruit bunch is the main solid waste from oil palm obtained from
milling process. This biomass can be used as an alternative energy for combustion
purposes especially in industry. Unfortunately, due to its poor physical properties
EFB is not normally utilized as fuel. However, it can be use in optimise by upgrading
and treating its properties. The method that can be used is the briquetting technique.
Briquetting is an alternative method in upgrading biomass into a useful solid fuel that
can be done through various technologies. In this project, EFB material will be mixed
up with the recycled papers and it will be turned into solid briquette through the
briquetting process. The used of recycle papers in this project is to utilized the
abundant papers into something useful, thus helps in reducing the number of
municipal wastes generated every year. Papers are selected as a material to be used
compared to the other types of recycled wastes such as glass and plastic because it is
known to be a good material for a combustion ignition. As for plastics, it may be
compatible to papers to be used as ignition material in combustion, but it will spread
a toxic gas while it is burn.
3
1.3
Objectives
There are several aims that need to be achieved in this project which is
(a)
Determination of the best ratios of EFB and recycled papers for
combustion.
(b)
To develop a solid fuel from the mixing of an empty fruit bunch
(EFB) and recycled papers at a different ratio/percentage.
1.4
Scopes of study
The scope of this project is mainly focusing on the mixing of the empty fruit bunch,
EFB and the recycled papers. All these palm oil mills is to be obtained, mixed up and
to be develop as a fuel briquette at a certain ratio or percentage with the EFB as the
major element. This fuel briquette is to be carried out with the performance tests and
comparison tests in terms of its calorific values, stability, and durability, proximate,
ultimate, immerse and crack. Other aspects of the material will not be covered.
1.5
Thesis Frames
The organization of this report is as follow; Chapter 1 as the beginning of the report
is providing the introduction of the project. The elements that consist in Chapter 1 is
background of palm oil industry and its application in industry, followed by a
problem statement of the project study, an objectives that aimed in this study, scopes
of project study and report organization. Chapter 2 comprised of a literature review
of previous research regarding the palm biomass briquettes and types of testing that
the material have gone through. Chapter 3 present the methodology of the research.
In this chapter, all the equipment and type of testing that will be used in the study is
stated. All the working flow during the study will be guided by using a Gantt chart.
Meanwhile the result for the testing proposed in Chapter 3 is presented in Chapter 4.
In this chapter, all the data regarding to the testing conducted is compiled in one
4
chapter. Here, a complete discussion and analyses on the data recorded is made to
choose the best ratio of sample briquette to achieve the objective in this research.
Finally, in Chapter 5, a conclusion on the overall project is made and a
recommendation to improve the research is proposed. Gantt Chart II is used as a
guidance to complete the analysis of the data.
5
SOLID FUEL FROM EMPTY FRUIT BUNCH FIBER AND
RECYCLED MATERIAL
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Materials) with Honors.
By
NIKMAH BINTI ABD MUIN
FACULTY OF MANUFACTURING ENGINEERING
2010
DECLARATION
I hereby, declared this report entitled “Solid Fuel from Empty Fruit Bunch and
Recycled Material” is the results of my own research except as cited in references.
Signature
:
……………………………….
Author’s Name
:
NIKMAH BINTI ABD MUIN
Date
:
18th May 2010
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Engineering Materials) with Honors. The member of the supervisory
committee is as follow:
………………..………………………
(Principal Supervisor)
(MOHD YUHAZRI BIN YAAKOB)
ABSTRACT
This research purpose is to study and analyze the effect of different ratio from the
mixture of Empty Fruit Bunch Fiber (EFB) and recycled material briquettes towards the
combustion properties. This research also aims to utilize the abundant materials such as
palm biomass and waste papers into a useful product to minimize the quantity of wastes
produced in this country. The main raw materials used in this study are EFB fiber and
waste papers. Basically, these two materials were mixed up and turned into solid fuel
briquettes by briquetting technology. The mixtures were compacted into a solid briquette
using a hydraulic compression machine. The typical pressure applied to compress the
briquette is 12 000 lb. After that, the briquettes have undergone two types of testing
which is chemical testing and mechanical testing. All the testing conducted were referred
according to the standard test methods provided by ASTM standard. Types of chemical
testing tested onto the fuel briquettes are moisture content test, ash content test,
combustion test, gas emission test and combustion analysis. As for the mechanical
testing, types of testing that have been conducted are crack test, stability test, water
resistance test, durability test and compression test. From the testing, the best ratio of the
biomass briquettes were observed and selected. From the analyses of both chemical and
mechanical testing, it was found that sample briquette with ratio 60:40 has given a
highest value of heat released which is 162.77 kJ, whereas sample with ratio 40:60 has
good burning time, and better compressive strength. Meanwhile, sample ratio of 50:50
has produced lowest ash content and sample ratio 90:10 has given the lowest gas
emission of carbon, nitrogen and sulfur and the best sample that sustained its
dimensional stability.
i
ABSTRAK
Kajian ini dijalankan adalah bertujuan untuk mengkaji dan menganalisa kesan tenaga
pembakaran yang berlaku terhadap campuran dua bahan mentah iaitu Empty Fruit Bunch
(EFB) dan bahan yang boleh dikitar semula pada kadar nisbah yang berbeza – beza.
Kajian ini juga turut dihasilkan dengan matlamat untuk menggunakan bahan – bahan
terbuang seperti hasil buangan kelapa sawit dan bahan terbuang pada tahap yang
optimum bagi mengurangkan kuantiti bahan terbuang yang dihasilkan dalam negara
pada setiap tahun. Bahan utama yang akan terlibat dalam projek ini ialah EFB dan kertas
terbuang. Secara keseluruhannya, EFB dan kertas terbuang tersebut akan dihancurkan
dan dicampurkan menjadi satu adunan bagi menghasilkan sampel berbentuk pepejal
yang dikenali sebagai “briquette”. Hasil campuran tersebut akan dimampatkan ke dalam
bentuk pepejal menggunakan mesin mampatan pada tekanan 12 000 lb. Selepas pepejal
briquette berjaya dibentuk, ia akan melalui dua jenis ujian iaitu ujian kimia dan ujian
mekanikal. Ujian kimia yang akan dilakukan adalah seperti ujian kelembapan, ujian
isipadu abu yang dihasilkan selepas pembakaran,ujian pembakaran, ujian pembebasan
gas dan ujian analisa pembakaran. Manakala ujian mekanikal yang terlibat adalah seperti
ujian keretakan, ujian kestabilan, ujian ketahanan, uijan ketahanan pada air, dan akhir
sekali ujian mampatan. Berdasarkan ujian – ujian tersebut, nisbah 60:40 telah memberi
nilai haba pembebasan yang paling tinggi iaitu sebanyak 162.77 kJ, manakala nisbah
40:60 telah memberikan masa pembakaran yang paling lama dan nilai kekuatan tekanan
yg paling baik. Sementara itu, nisbah 50:50 telah menunjukkan nilai abu yg paling
rendah selepas pembakaran dah nisbah 90:10 merekodkan nilai pembebasan gas paling
rendah disamping mampu mengekalkan kestabilannya dengan baik.
ii
DEDICATION
For my beloved family especially my parents Abd Muin B. Ahmad and
Kalthom Binti Hasan and friends
iii
ACKNOWLEDGEMENT
I would like to convey my thanks to the all person who had contributed in ensuring a
successful occurrence throughout the duration of my final year project. I also gratefully
acknowledge to my PSM supervisor, Encik Yuhazri Bin Yaakob, for his encouragement,
fully support, by providing me enormous guidance and idea for my research project.
Without them all, this project may not valuable. Their knowledge and experience has
fully inspired, motivated and drive me to complete my final year project successfully.
Also, my special thanks to
all my peers, especially Siti Faizah, Nur Rifhan, Nurfarizan and Nurhashima, and to
those who are undergoing final year in Degree programs, thanks for your all kindness of
delivering ideas and motivation that necessary for me to complete this study. Besides
those mentioned, I also would like to express my gratitude with highly appreciation and
dedication to my family because without them, I won’t be here to complete my study in
Universiti Teknikal Malaysia, Melaka.
iv
TABLE OF CONTENTS
TOPICS
CHAPTER
1
2
PAGES
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Contents
v
List of Tables
ix
List of Figures
xi
List of Symbols
xiv
List of Abbreviations
xv
INTRODUCTION
1
1.1
Background of Study
1
1.2
Problem Statements
3
1.3
Objectives
4
1.4
Scope of Study
4
1.5
Thesis Frame
4
LITERATURE REVIEW
6
2.1
Biomass
6
2.1.1
Biomass Energy Potential
7
2.1.2
Availability of Biomass in Malaysia
8
2.2
Oil Palm
10
2.2.1
11
Oil Palm Biomass and Energy Content
v
2.2.2
2.3
Empty Fruit Bunch
13
Solid Fuel via Briquetting Technology
14
2.3.1
15
Fuel Briquettes
2.3.1.1 Production of Fuel Briquettes
From Waste Paper and Coconut
Husk Admixtures
2.3.2
16
2.3.1.2 Summary of Journal
17
Briquetting Process
18
2.3.2.1 Production of Palm Based
Biomass Briquettes
2.3.2.2 Summary of Journal
2.4
20
Municipal Solid Waste
21
2.4.1
Solid Waste Generation in Malaysia
21
2.4.2
Fiber Energy Recovery: Use of
Wastepaper as Fuel
3
18
24
2.5
Binder System
24
2.6
Chemical Properties Analysis
25
2.7
Mechanical Properties Analysis
27
2.8
Summary of Literature View
30
METHODOLOGY
31
3.1
Introduction
31
3.2
Materials
33
3.2.1 Empty Fruit Bunch
33
3.2.2 Recycled Paper
34
Sample Preparation
34
3.3.1 Raw Material Preparation
35
3.3
3.3.1.1 Drying
35
3.3.1.2 Blending
36
3.3.2 Sample Fabrication
3.3.2.1 Blending Ratios
vi
37
39
3.3.2.2 Addition of Binder
3.4
Laboratory Testing
41
3.4.1
Chemical Testing
42
3.4.1.1 Combustion Test
42
3.4.1.2 Ash Content
43
3.4.1.3 Moisture Content
43
3.4.1.4 Gas Emission
43
3.4.1.5 Combustion Analysis
44
Mechanical Testing
45
3.4.2.1 Compression Test
45
3.4.2.2 Water Resistance Test
46
3.4.2.3 Stability Test
47
3.4.2.4 Crack Test
47
3.4.2
4
40
RESULTS & DISCUSSIONS
48
4.1
Specimen
48
4.2
Experimental Work
50
4.3
Result of Chemical Properties Analyses
54
4.3.1
Combustion Testing
54
4.3.1.1 Combustion Test for S/N 1
55
4.3.1.2 Combustion Test for S/N 2
56
4.3.1.3 Combustion Test for S/N 3
57
4.3.1.4 Combustion Test for S/N 4
58
4.3.1.5 Combustion Test for S/N 5
59
4.3.1.6 Combustion Test for S/N 6
60
4.3.1.7 Comparison on Overall Briquettes
61
4.4
Results of Mechanical Testing Analyses
73
4.2.1
Compression Test
73
4.2.1.1 Compression Test for S/N 1
75
4.2.1.2 Compression Test for S/N 2
76
4.2.1.3 Compression Test for S/N 3
77
vii
5
4.2.1.4 Compression Test for S/N 4
77
4.2.1.5 Compression Test for S/N 5
78
4.2.1.6 Compression Test for S/N 6
79
4.2.1.7 Comparison on Overall Briquettes
80
4.2.2
Stability Test
84
4.2.3
Crack Test
87
4.2.4
Immerse Test
89
CONCLUSION & RECOMMENDATION
90
5.1
Conclusion
90
5.2
Recommendation
91
REFERENCES
92
APPENDICES
A
Gantt chart of PSM I
B
Gantt chart of PSM II
C
Compression test results
viii
LIST OF TABLES
NO.
TITLE
PAGES
1.1
Palm Biomass generated in year 2005
2
2.1
Oil Palm planted areas and FFB production in 2005
9
2.2
Oil Palm Biomass Energy Potential
9
2.3
Heat value of Oil Palm Biomass (KCAL/Kg, dry)
12
2.4
Energy database for Palm Biomass
12
2.5
Different shapes of fuel briquettes
15
2.6
Solid waste composition locations in Peninsular Malaysia
22
2.7
MSW generated in Kuala Lumpur in 2002
23
2.8
Kuala Lumpur’s solid composition (1975 – 2000)
23
2.9
Properties of the raw materials and Palm based biomass briquettes 26
2.10
Analysis results of the olive refuse and paper mill waste samples
26
2.11
Briquettes moisture content
27
2.12
Equilibrium moisture content and density of the briquette
28
2.13
Durability rating of the briquettes
29
2.14
Dimensional changes in briquettes after 3-day immersion in water 30
3.2
Properties of EFB as raw materials
3.3
Sample identification of EFB and recycled paper by weight percent 39
3.4
Sample identification of solid briquette by weight of binder
40
4.1
Sample ratio and its serial number
49
4.2
Enthalpy of various element
62
4.3
Heat released for each sample briquettes
63
4.4
Ash content and percentage of ash for sample briquettes
66
4.5
Comparison of ash content
69
4.6
Amount of gas emission in sample briquettes
70
ix
33
4.7
Maximum load, compressive strength and modulus of sample
80
4.8
Stability of fuel briquettes
84
4.9
Percentage of water absorption of fuel briquettes
89
4.10
Dimensional changes of briquettes after 24 hours immersed
90
x
LIST OF FIGURES
NO.
TITLE
PAGES
2.1
Types of Biomass in Malaysia
9
2.2
Cross section of an oil palm fruit.
10
2.3
Oil palm trees in Malaysia
11
2.4
Palm Biomass
11
2.5
(a) An empty fruit bunch (EFB) and (b) it fibrous form
14
2.6
Samples briquettes produced with 100 % wastepaper
16
2.7
Samples of wastepaper-coconut husk briquettes
17
2.8
Palm based biomass briquetting process
19
2.9
(a) EFB Powder, (b) EFB Fibre and (c) Sawdust.
20
2.10
(a) EFB Briquette (b) EFB Powder + Sawdust (50:50)
(c) EFB Powder + Sawdust (40:60)
2.11
20
Solid waste composition of selected locations in Peninsular
Malaysia
22
3.1
Methodology Process Flow Chart
32
3.2
EFB fibrous form
33
3.3
(a) Paper Shredder Machine and (b) Shredded Paper
34
3.4
Process flow of raw material Preparation
35
3.5
Drying Oven
36
3.6
EFB Powder.
36
3.7
Cylindrical with a hollow shape of the fuel briquette
37
3.8
Hydraulic Press Machine
38
3.9
Fabrication process of solid fuel briquette
38
3.10
Digital Weighing Machine
39
3.11
Addition of starch in the mixture as binding agent
40
3.12
Types of testing on sample briquette
41
3.13
Gasifier for combustion test
42
xi
3.14
Gas particle analyzer
44
3.15
Burning Profile of Oil Palm Briquettes
44
3.16
Universal Testing Machine
45
3.17
Position of sample briquette on test machine
46
3.18
Set up for crack test
47
4.1
Solid briquette
49
4.2
Sample briquettes produced in different ratios
50
4.3
Method of preparing blending waste paper
51
4.4
Method of mixing the EFB with waste paper
52
4.5
Method of briquetting sample briquette
53
4.6
Method of ejecting compacted briquette
53
4.7
Graph of temperature vs. time for S/N 1
55
4.8
Graph of temperature vs. time for S/N 2
56
4.9
Graph of temperature vs. time for S/N 3
57
4.10
Graph of temperature vs. time for S/N 4
58
4.11
Graph of temperature vs. time for S/N 5
59
4.12
Graph of temperature vs. time for S/N 6
60
4.13
Graph of comparison on overall sample briquette
61
4.14
Comparison of heat released of sample briquettes
64
4.15
Percentage of ash in briquettes
67
4.16
Comparison in percentage of ash with journal
68
4.17
Comparison of sample S/N 5 with journal
69
4.18
Percentage of Oxygen and carbon dioxide in briquettes
71
4.19
Comparison of gas emission of solid briquettes
73
4.20
Position of sample briquette in lateral
74
4.21
Compression test of sample briquette
74
4.22
Sample briquette after compressed
75
4.23
Graph of compressive load for S/N 1
75
4.24
Compression graph for S/N 2
76
4.25
Compression graph for S/N 3
77
4.26
Compression graph for S/N 4
77
xii
4.27
Compression graph for S/N 5
78
4.28
Compression graph for S/N 6
79
4.29
Comparison of compressive load on samples
80
4.30
Histogram of compressive strength on overall briquettes
81
4.31
Comparison of sample briquettes with other journal
83
4.32
Stability test on fuel briquette
84
4.33
Bar graph on stability result of briquettes
85
4.34
Crack test results
88
4.35
Water immerse test result
90
xiii
LIST OF SYMBOL
°C
-
Celcius
e.m.c
-
electromagnetic compatibility
g/min
-
gram per minute
GPa
-
giga pascal
kJ/kg
-
Kilo Joule per kilogram
kN
-
Kilo Newton
kW
-
kilo watt
MPa
-
mega pascal
m
-
micro meter
mm
-
millimeter
N/m2
-
Newton per meter
%
-
Percentage
lb
-
Pound
S/N
-
Serial Number
w.t %
-
Weight Percent
xiv
LIST OF ABBREVIATION
BBQ
-
Barbeque
CPO
-
Crude Palm Oil
C
-
Carbon
CO2
-
Carbon Dioxide
CV
-
Calorific Value
EFB
-
Empty Fruit Bunch
EPSM
-
Environment Protection Society Malaysia
FEFB
-
Fiber Empty Fruit Bunch
FFB
-
Fresh Fruit Bunch
GCV
-
Gross Calorific value
H
-
Hydrogen
HHV
-
High Heating Value
KL
-
Kuala Lumpur
LHV
-
Lower Heating Value
N
-
Nitrogen
NOx
-
Nitrogen Monoxide
MPOB
-
Malaysian Palm Oil Board
MSW
-
Municipal Solid Waste
NCV
-
Net Calorific Value
PEFB
-
Pulverized Empty Fruit Bunch
PORIM
-
International Palm Oil Congress
RM
-
Ringgit Malaysia
SOx
-
Sulphur Monoxide
UN
-
United Nation
UV
-
Ultra Violet
WRI
-
Water Resistance Index
WTE
-
Waste – to – energy
xv
CHAPTER 1
INTRODUCTION
1.1
Background of study
Malaysian palm oil industry has grown tremendously over the last 4 decades, and
since then it has maintained its position as the leading world’s country in the
production of palm oil (Nasrin, A.B., et al., 2008). The Malaysian Palm Oil industry
recorded a mixed performance in 2005 due to continue in strong growth in
production. The oil palm is the prolific producer of biomass. Oil constitutes only
about 10 percent of the palm production while the rest is biomass (Yusof, B., and
Weng, C.K., 2004). The prices and export earnings dipped, despite an increase in
exports of all oil palm products during the year. The total oil palm planted area
increased by 4.5 percent or 174,000 hectares to 4.0 million hectares in year 2005.
Sabah remained the largest oil palm planted state with 1.2 million hectares or 30 %
of the total planted area (Basri, W., 2006). Since the oil crisis in 1970’s the use of
biomass as a source of energy is a topic of growing interest and debate (Ma, A.N.,
and Yusuf, B., 2005). Nevertheless, the industry has also generated a vast amount of
palm biomass, mainly from milling and crushing palm kernel. The types and amounts
of these biomass generated in year 2005 are tabulated in Table 1.1 (Nasrin, A.B., et
al., 2008). The oil consists of only a minor fraction of the total biomass produced in
the plantation. The remainder consists of huge amount of lignocelluloses materials in
the forms of fronds, trunk and empty fruit bunch (EFB). EFB is the main solid waste
obtained from milling process. However, due to its poor characteristic, it has
limitation to be used as fuel.
1
Table 1.1: Palm Biomass generated in year 2005. (Nasrin, A.B., et al., 2008)
Producing energy from renewable biomass is only one of the various ways of
responding to the challenges of the energy crisis. In 2004, Malaysia had about 3.87
million hectares of land under oil palm cultivation. Currently, more than 80 % of the
oil palm produced is used for food applications like cooking oil, frying oil and many
others. Oil palm is a perennial crop. It has an economic life span of about 25 years.
Traditionally, oil palm is grown for its oil example like palm oil, palm kernel oil, and
palm kernel cake as the community products. Besides palm oil and palm kernel, oil
palm industry generates large quantity of biomass residue which is side products as
stated before like fronds, trunks, EFB, palm oil mill effluent, palm fibre and shell that
have not been fully commercially exploited. Through concerted research and
development efforts by many research organizations including Malaysian Oil Palm
Board (MPOB), this co – products from palm oil industry have been found to be
good resources for many application. There are many competitive uses of these
materials. One of them is to utilize them as a fuel for energy production. In fact,
Malaysian government has identified biomass as fifth fuel resource to compliment
the petroleum, gas, coal, and hydro as energy resources. Palm biomass has been
identified as a single most important energy source. On the other hands, the main
sources of biomass in Malaysia are domestic wastes, agricultural wastes, effluent
sludge and wood chips.
Biomass energy systems can be based on a wide range of feedstock. They use many
different conversion technologies to produce solid, liquid, and gaseous fuels. These
can then be used to provide heat, electricity and fuels to power vehicles; using
burners, boilers, generators, internal combustion engines, turbine or fuel cells. Power
can be generated by co – firing a small portion of biomass on existing power plant,
2
burning biomass in conventional steam boilers, biomass gasification and anaerobic
digestion (PORIM International Palm Oil Congress, 1996).
Converting palm biomass into a uniform and solid fuel through briquetting process
appears to be an attractive solution in upgrading its properties and add value. (Nasrin,
A.B., et al., 2008). Biomass briquette is the process of converting low bulk density
biomass into high density and energy concentrated fuel briquettes. Biomass briquette
plant is of various sizes which converts biomass into a solid fuel. Briquettes are ready
substitute of coal or wood in industrial boiler and brick kiln for thermal application.
Biomass briquettes are non conventional source of energy, renewable in nature, eco –
friendly, non polluting and economical. Process of converting biomass into solid fuel
is non polluting process. It involves drying, cutting, grinding, and pressing with or
without the aid of a binder.
1.2
Problem statement
Malaysia has involved in palm oil industry over the last four decades and since then
it has generated vast quantities of palm biomass, mainly from milling and crushing
palm kernel. Empty fruit bunch is the main solid waste from oil palm obtained from
milling process. This biomass can be used as an alternative energy for combustion
purposes especially in industry. Unfortunately, due to its poor physical properties
EFB is not normally utilized as fuel. However, it can be use in optimise by upgrading
and treating its properties. The method that can be used is the briquetting technique.
Briquetting is an alternative method in upgrading biomass into a useful solid fuel that
can be done through various technologies. In this project, EFB material will be mixed
up with the recycled papers and it will be turned into solid briquette through the
briquetting process. The used of recycle papers in this project is to utilized the
abundant papers into something useful, thus helps in reducing the number of
municipal wastes generated every year. Papers are selected as a material to be used
compared to the other types of recycled wastes such as glass and plastic because it is
known to be a good material for a combustion ignition. As for plastics, it may be
compatible to papers to be used as ignition material in combustion, but it will spread
a toxic gas while it is burn.
3
1.3
Objectives
There are several aims that need to be achieved in this project which is
(a)
Determination of the best ratios of EFB and recycled papers for
combustion.
(b)
To develop a solid fuel from the mixing of an empty fruit bunch
(EFB) and recycled papers at a different ratio/percentage.
1.4
Scopes of study
The scope of this project is mainly focusing on the mixing of the empty fruit bunch,
EFB and the recycled papers. All these palm oil mills is to be obtained, mixed up and
to be develop as a fuel briquette at a certain ratio or percentage with the EFB as the
major element. This fuel briquette is to be carried out with the performance tests and
comparison tests in terms of its calorific values, stability, and durability, proximate,
ultimate, immerse and crack. Other aspects of the material will not be covered.
1.5
Thesis Frames
The organization of this report is as follow; Chapter 1 as the beginning of the report
is providing the introduction of the project. The elements that consist in Chapter 1 is
background of palm oil industry and its application in industry, followed by a
problem statement of the project study, an objectives that aimed in this study, scopes
of project study and report organization. Chapter 2 comprised of a literature review
of previous research regarding the palm biomass briquettes and types of testing that
the material have gone through. Chapter 3 present the methodology of the research.
In this chapter, all the equipment and type of testing that will be used in the study is
stated. All the working flow during the study will be guided by using a Gantt chart.
Meanwhile the result for the testing proposed in Chapter 3 is presented in Chapter 4.
In this chapter, all the data regarding to the testing conducted is compiled in one
4
chapter. Here, a complete discussion and analyses on the data recorded is made to
choose the best ratio of sample briquette to achieve the objective in this research.
Finally, in Chapter 5, a conclusion on the overall project is made and a
recommendation to improve the research is proposed. Gantt Chart II is used as a
guidance to complete the analysis of the data.
5