Analysis of biomass-residue-based cogeneration system in palm oil mills

Published Date
Biomass and Bioenergy
February 2003, Vol.24(2):117–124, doi:10.1016/S0961-9534(02)00101-0

• Author 

• Z. Husain ^,
• Z.A. Zainal
• M.Z. Abdullah

• School of Mechanical Engineering, Engineering Campus, University Science Malaysia, 14300 Nibong Tebal Seberang Perai Seletan, Pulau Pinang, Malaysia

Received 5 November 2001. Revised 10 July 2002. Accepted 19 July 2002. Available online 6 December 2002. 

Abstract

Palm oil mills in Malaysia operate on cogeneration system using biomass residue as fuel in the boiler. The boiler produces high pressure and temperature steam which expands in a backpressure steam turbine and produces enough electric power for the internal needs of the mill. The exhaust steam from the turbine goes to an accumulator which distributes the steam to various processes in the mill.

The study were made on seven palm oil mills in the Perak state in Malaysia. The primary objectives of the study are to determine boiler and turbine efficiencies, energy utilization factor, oil extraction rate and heat/power ratio for various palm oil mills working under similar conditions and adopting same processes. The palm oil industry is one of those rare industries where very little attempt is made to save energy. The energy balance in a typical palm oil mill is far from optimum and there is considerable scope for improvement. Bench-marking is necessary for the components in the mill. Energy-use bench-marking can give an overview of energy performance of the mills. The calculations were done to get net gain in power when back pressure turbine is replaced by a condensing turbine.

It was found that the boiler and turbine have low thermal efficiencies compared to conventional ones used in power plants due to non-homogeneity and non-uniform quality of the fuel. The extraction rate was around 0.188. The use of condensing turbine increase the power output by 60% and the utilization factor was found to be 65% for the cogeneration system.

Keywords

Biomass

Shell

Fiber

Fresh fruit bunch

Empty fruit bunch

Palm oil mill

CHP (combined heat and power)

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Nomenclature

B

boiler

T

turbine

C

condenser

G

generator

P

pressure

T

temperature

CV

calorific value

TNB

Tenaga Nasional Berhad (National Electricity Board)

MPOB

Malaysia Palm Oil Board

h_f

sp. enthalpy of saturated water

h_fg

sp. enthalpy of vapor

h_g

sp. enthalpy of saturated steam

h

sp. enthalpy of superheated steam

m_f

biomass residue consumption in  

m_s

capacity of boiler in  

x

moisture content (%)

FFB

fresh fruit bunch

EFB

empty fruit bunch

Fig. 1.

 Table 1

Table 1.

 Table 2

Table 2.

 Table 3

Table 3.

 Table 4

Table 4.

 Table 5

Table 5.

 Table 6

Table 6.

 Table 7

Table 7.

 Table 8

Table 8.

• *
  Corresponding author. Tel.: +604-593-7788; fax: +604-594-1025

Copyright © 2002 Published by Elsevier Ltd.

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