How to mitigate greenhouse gas emissions by using co-products
ifeu – Institut für Energie- und Umweltforschung Heidelberg How to mitigate greenhouse gas emissions by using co-products arising from palm oil production Nils Rettenmaier, Heiko Keller & Guido A. Reinhardt 8th annual World Biofuels Markets Congress and Exhibition Malaysian Palm Oil Council Workshop Rotterdam, 12 March 2013 Oil palm biomass use Co-product use Trunks Plantation FFB Palm kernels Wood products Use as furniture Wood chips Energy use Palm kernel oil Cosmetics Energy Export of surplus Mesocarp fibre Palm kernel shells Palm oil mill EFB Crude palm oil POME Transport Glycerine Processing Biodiesel process Use in chemical industry Carotenes Tocotrienols Use in food industry Phytosterols Legend: Biodiesel Product Use in food industry Use as transportation fuel Main product use Process Oil palm biomass use Replanting of plantations: Using oil palm trunks Oil palm biomass use Conceptual trend of oil palm biomass utilisation Source: Ng et al. (2012): Waste-to-wealth: green potential from palm biomass in Malaysia. Journal of Cleaner Production 34, 57-65. Oil palm biomass use Products from oil palm trunks With courtesy of MPOC Oil palm biomass use Phytonutrients Vitamin E (tocotrienols) Vitamin A (carotenes) Phytosterols With courtesy of MPOC Project background • Greenhouse gas balance of selected optimisation strategies along the palm oil chain • Oil palm trunk use • Phytonutrient extraction and use Outline Oil palm biomass use Studying environmental impacts Selected optimisations 1. Oil palm trunk use 2. Extraction of phytonutrients Conclusions & Recommendations Environmental impacts Environmental advantages and disadvantages: + – • CO2 neutral • Land use • Save energetic resources • Eutrophication of surface water • Organic waste reduction • Water pollution by pesticides • Less transport • Energy intensive production • etc. • etc. Total: positive or negative ? Life cycle assessment (LCA) ISO 14040 & 14044 Goal and scope definition Inventory analysis Impact assessment Interpretation LCA: Life cycle comparison Crude oil Palm oil Credits Fertiliser Fuel Resource extraction Raw material production Pesticides Reference system Agriculture Transport Processing Utilisation Co-products Equivalent products Life cycle assessment (LCA) ISO 14040 & 14044 Goal and scope definition Inventory analysis Impact assessment Interpretation LCA: Inventory analysis Inputs Outputs Crude oil Palm oil e.g.: Fertiliser Fuel - natural gas - crude oil - brown coal - hard coal - uranium - water Resource extraction Raw material production Transport Processing Utilisation Pesticides Agriculture e.g.: - CO2 SO2 CH4 NOX NH3 N2O HCl CO C6H6 VOC Life cycle assessment (LCA) ISO 14040 & 14044 Goal and scope definition Inventory analysis Impact assessment Interpretation LCA: Impact assessment Impact category Parameter Substances (LCI) Resource depletion Sum of depletable primary energy carriers Crude oil, natural gas, coal, uranium, … Mineral resources Lime, clay, metal ores, salt, pyrite, … Water Water Greenhouse effect CO2 equivalents Carbon dioxide, dinitrogen monoxide, methane, different CFCs, methyl bromide, … Ozone depletion CFC-11 equivalents CFC, halons, methyl bromide, dinitrogen monoxide… Acidification SO2 equivalents Sulphur dioxide, hydrogen chloride, nitrogen oxides, ammonia, … Terrestrial & aquatic eutrophication PO4 equivalents Nitrogen oxides, ammonia, phosphate, nitrate Summer smog C2H4 equivalent Hydrocarbons, nitrogen oxides, carbon monoxide, chlorinated hydrocarbons, … Methodology for LCA experts • Screening greenhouse gas (GHG) balances • Largely following ISO standards 14040 and 14044 on product life cycle assessment (LCA) • Carbon footprint study as a first step towards a more comprehensive sustainability assessment • Co-product handling • Substitution approach (EU Renewable Energy Directive stipulates allocation approach for biofuel GHG balances) Outline Oil palm biomass use Studying environmental impacts Selected optimisations 1. Oil palm trunk use 2. Extraction of phytonutrients Conclusions & Recommendations Oil palm biomass use Co-product use Trunks Plantation FFB Palm kernels Wood products Use as furniture Wood chips Energy use Palm kernel oil Cosmetics Energy Export of surplus Mesocarp fibre Palm kernel shells Palm oil mill EFB Crude palm oil POME Transport Glycerine Processing Biodiesel process Use in chemical industry Carotenes Tocotrienols Use in food industry Phytosterols Legend: Biodiesel Product Use in food industry Use as transportation fuel Main product use Process Oil palm trunk use: Goal & scope • Evaluation of the use of oil palm trunks for • Furniture and • Bioenergy… • …as compared to the conventional practise (push-felling, chopping and in-situ decay) in terms of greenhouse gas emission savings • Challenge: • Difficult material properties of oil palm wood (e.g. high moisture content) and relatively high energy demand for wood drying Oil palm trunk use: Furniture Palm trunk harvest Transport Sawing Impregnating & Drying Moulding & Sizing Boards, shelves Oil palm trunk use: Furniture Production of furniture from oil palm trunks Conventional practise Wood products from oil palm trunks Managed forest Palm trunk harvest Spruce wood Oil palm trunks Rotting of palm trunks Fertiliser Sawdust wet Landfill Transport Natural gas Combustion (for energy) Woodworking industry Sawing Impregnating & Drying Moulding & Sizing Boards, shelves Boards, shelves Transport Transport Usage Usage Combustion Combustion Residue wood Oil / gas Energy provision Power Sawdust dry Pelleting Animal bedding Straw Legend: Product Process Natural gas Natural gas Reference system Oil palm trunk use: Furniture Greenhouse gas emissions from furniture production Advantages Furniture production Disadvantages Palm Conventional Inefficient heat gen. Net kg CO2 eq. / t fresh palm trunks Electricity HighSteam GHG drying Diesel in factoryemissions due to Transports Other inputs Credit energy from unused spruce wood Compensation fertiliser Net total Credit energy from used palm wood furniture Entire life cycle of spruce wood furniture Rotting of saw dust Net over all IFEU 2013 Oil palm trunk use: Furniture Production of furniture from oil palm trunks Conventional practise Wood products from oil palm trunks Managed forest Palm trunk harvest Spruce wood Oil palm trunks Transport Natural gas Combustion (for energy) Woodworking industry Sawing Impregnating & Drying Moulding & Sizing Boards, shelves Boards, shelves Transport Transport Usage Usage Combustion Combustion Rotting of palm trunks Fertiliser Extra trunks for heat Sawdust wet Landfill Residue wood Oil / gas Energy provision Power Sawdust dry Pelleting Animal bedding Straw Legend: Product Process Natural gas Natural gas Reference system Oil palm trunk use: Furniture Greenhouse gas emissions from furniture production Advantages Disadvantages Furniture production Palm Conventional Inefficient heat gen. Net Palm Conventional Net Extra trunks for heat Palm Conventional Efficient heat gen. Net Palm Combined Conventional heat / power Net Net over all -600 -400 -200 0 200 kg CO2 eq. / t fresh palm trunks Steam Electricity GHG emission savings if process Diesel in factory Transports energy is produced Other inputs Credit energy from used palm wood furniture efficiently from palm wood Credit energy from unusedoil spruce wood Entire life cycle of spruce wood furniture Compensation fertiliser Net total Rotting of saw dust Net over all IFEU 2013 Oil palm trunk use: Bioenergy Production of bioenergy from oil palm trunks Oil palm plantation Rotting of palm trunks Fertiliser Palm trunks Chipping Power Pre-drying Combustion Heat Drying Dry wood chips Legend: Transport Product Process Reference system Power Power Natural gas Heat Heat Natural gas Combustion Oil palm trunk use: Bioenergy Greenhouse gas emissions from bioenergy production Advantages Disadvantages Bioenergy production Palm Net Palm Net Palm Net Inefficient heat gen. Efficient heat gen. Combined heat / power Net over all -200 -150 -100 -50 0 50 100 150 kg CO2 eq. / t fresh palm trunks Steam Transports Compensation fertiliser Net over all Electricity Credit energy from palm wood chips Net total IFEU 2013 GHG emission savings, especially if drying is efficient Oil palm trunk use: Comparison Sensitivity analyses for most important parameters Disadvantages Advantages Standard scenarios Furniture production Heat / power drying + 30 % Heat / power drying - 30 % Transports by truck + 30 % Transports by truck - 30 % Power mix EU: coal No methane from wet saw dust Bioenergy production Standard scenarios Heat / power drying + 30 % Heat / power drying - 30 % Transports by truck + 30 % Transports by truck - 30 % Power mix EU: coal -250 -200 -150 -100 -50 0 50 kg CO 2 eq. / t fresh palm trunks 100 IFEU 2013 Results relatively robust; heat for drying decisive Oil palm trunk use: Future potential • Aim: Exemplifying the large-scale use of oil palm trunks • Basic idea: export of furniture or wood chips to existing markets for such products made from wood • Taking Malaysia as an example, but results are transferable to other parts of the world (at least as a realistic estimation) • Boundary conditions for this scenario calculation • 20 million palm trees felled per annum • Recovery rate: 30 – 70 % due to geography and logistics • Moisture: 67 % • Results expressed per ‘inhabitant equivalent’ • 1 inhabitant equivalent = per capita (GHG) emissions of one Malaysian citizen during one year Oil palm trunk use: Future potential Potential annual greenhouse gas emission savings in Malaysia 1000 t CO2 equivalents -850 -750 -650 -550 -450 -350 -250 -150 -50 50 Inefficient heat gen. using 30% of trunks Furniture production Efficient heat gen. using 50% of trunks Comb. heat / power using 70% of trunks Inefficient heat gen. using 30% of trunks Bioenergy production Efficient heat gen. using 50% of trunks Comb. heat / power using 70% of trunks -120 -100 -80 -60 -40 1000 inhabitant equivalents -20 0 20 IFEU 2013 Large future potential in all CPO-producing countries Outline Oil palm biomass use Studying environmental impacts Selected optimisations 1. Oil palm trunk use 2. Extraction of phytonutrients Conclusions & Recommendations Oil palm biomass use Co-product use Trunks Plantation FFB Palm kernels Wood products Use as furniture Wood chips Energy use Palm kernel oil Cosmetics Energy Export of surplus Mesocarp fibre Palm kernel shells Palm oil mill EFB Crude palm oil POME Transport Glycerine Processing Biodiesel process Use in chemical industry Carotenes Tocotrienols Use in food industry Phytosterols Legend: Biodiesel Product Use in food industry Use as transportation fuel Main product use Process Phytonutrients: Goal & scope • Evaluation of an innovative palm oil biodiesel process (including the extraction of phytonutrients) and comparison to conventional palm oil biodiesel process in terms of greenhouse gas emission savings • Net impact per tonne of CPO • Potential impact on GHG balance of palm oil biodiesel • Challenge: counteracting effects • Positive: Credits for additional co-products • Negative: Higher process energy demand • Negative: Less biodiesel output Extraction of phytonutrients Conventional biodiesel process CPO Innovative biodiesel process CPO Legend: Product Fossil fuel Mineral oil Combustion (for energy) Equivalent chemicals PFAD Glycerine Pretreatment Pretreatment Deodorisation Deodorisation Mineral oil Diesel Palm oil biodiesel Palm oil biodiesel Reference system PFAD Combustion (for energy) Fossil fuel Glycerine Equivalent chemicals Mineral oil Tocotrienols Tocotrienols Mineral oil Carotenes Carotenes Mineral oil Phytosterols Phytosterols Soy oil Diesel Mineral oil Transesterification Transesterification + separation Process Extraction of phytonutrients Greenhouse gas emissions from phytonutrient extraction Expenditures Credits Innovative, standard vs. conventional Disadvantages Advantages Innovative, standard vs. conventional -0,1 0 0,1 0,2 0,3 t CO2 eq. / t crude palm oil Higher electricity consumption and less biodiesel Steam Power Methanol output potentially lead to additional GHG emissions Other inputs Credit biodiesel Credit glycerol tocotrienol Credit carotinoides Credit sterols But: specific Credit design of extraction process decisive Other credits Net total IFEU 2013 Extraction of phytonutrients Greenhouse gas emissions from phytonutrient extraction Expenditures Credits Innovative, high Innovative, standard Innovative, low Conventional process Difference, high Difference, standard Difference, low Advantages -4 -3 Disadvantages -2 -1 0 1 2 t CO2 eq. / t crude palm oil General statement on GHG emissions is impossible Other inputs Credit biodiesel Credit glycerol Credit tocotrienol Credit carotinoides Credit sterols Impact on biodiesel GHG balance: up to 3% improved Other credits Net total Steam Power Methanol IFEU 2013 Outline Oil palm biomass use Studying environmental impacts Selected optimisations 1. Oil palm trunk use 2. Extraction of phytonutrients Conclusions & Recommendations Conclusions Oil palm trunk use • Greenhouse gas emission savings - unless external energy is used - both in case wood products (furniture) or bioenergy (wood chips) are produced from oil palm trunks • Critical optimisation parameters: • Efficient process energy provision from oil palm trunks • Efficient wood drying units • Even better than export: local use of wood chips in CHP plants Extraction of phytonutrients • Potentially higher greenhouse gas emissions, but general statement impossible since results are largely dependent on specific design of extraction process • Critical optimisation parameters: • Energy required for purification • Minimisation of biodiesel losses Recommendations Implement oil palm trunk use • Further develop material use (furniture, plywood etc.) while aiming at optimum process design • Efficient energy provision and wood drying • No bulk landfilling of sawdust • Start lighthouse projects for bioenergy • Efficient energy provision and wood drying • Use synergies with palm oil mills • Surplus energy from palm oil mill residues, especially from palm oil mill effluent (POME) • Logistics • Prices (otherwise dependencies) • Full sustainability assessment before going large-scale Thank you for your attention ! Nils Rettenmaier Acknowledgements: We are deeply grateful to: Contact: nils.rettenmaier@ifeu.de + 49 - 6221 - 4767 - 0 / - 24 Downloads: www.ifeu.de • Dr Kalyana Sundram and Dr Yew Foong Kheong (both Malaysian Palm Oil Council, Malaysia) for having re-ceived excellent cooperation, fruitful discussions and provision of numerous data and information • Our colleagues at IFEU, Germany, for valuable fruitful discussions as well as for an internal quality control and review
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