Slide 1: POMEVap technology
POMEVap technology Amol Hukkerikar − Alfa Laval’s solution to palm oil mill effluent (POME) 27/10/2020 | © Alfa Laval 1 | www.alfalaval.com
Slide 2: Agenda
Agenda − What we’ll talk about today • Sustainability at Alfa Laval • Challenges faced by palm oil mills in treating effluent • POMEVap – Alfa Laval’s solution for tackling palm oil mill effluent • Recovery of oil from palm oil mill effluent (added income) • Towards zero liquid discharge in palm oil
Slide 3: Making our world better, every day
Making our world better, every day − Sustainability: A necessity and a business opportunity Our core technologies promote: • Responsible use of natural resources • Reduced environmental impact from industrial processes • Improved energy efficiency and heat recovery • Better water treatment and reduc
Slide 4: Turning wastewater into a valuable resource
Turning wastewater into a valuable resource − Alfa Laval’s POMEVap solution Value from wastewater Sustainable and efficient, Alfa Laval’s POMEVap • Creates clean, reusable water • Recovers valuable by- products or resources, such as oil 27/10/2020 | © Alfa Laval 4 | www.alfalaval.com
Slide 5: Challenges of treating palm oil mill effluent
Challenges of treating palm oil mill effluent 27/10/2020 | © Alfa Laval 5 | www.alfalaval.com
Slide 6: Growth in global palm oil production
Industry trends − Growth in global palm oil production 70 Colombia Others 2% 6% 60 Thailand Production (Million MT) 4% 50 40 30 20 Malaysia 29% Indonesia 10 59% 0 1970 1980 1990 2000 2010 2014 Production Indonesia Production Malaysia Production other countries Number of mills in the world ≈ 1,500 (M
Slide 7: Typical palm oil mill effluent loads
Typical palm oil mill effluent loads Palm oil mill effluent generation = 0.5–0.7 times mill capacity Mill capacity POME Oil in POME tons/hr (FFB) tons/hr tons/hr 30 15–21 0.15–0.21 45 22.5–31.5 0.22–0.31 60 30–42 0.3–0.42 75 37.5–52.5 0.37–0.52 90 45–63 0.45–0.63 27/10/2020 | © Alfa Laval 7 | www.al
Slide 8: Palm oil mill effluent or POME
Palm oil mill effluent or POME − Typical characteristics and properties Colour: Dark brown Temp: ≈ 80°C Sludge pit: POME collection Water: 94–95 % Non-oil solids: 4–5 % Oil: 0.8–1.0 % Non-toxic pH: 3.4–5.2 BOD: 10,000–45,000 ppm COD: 15,000–100,000 ppm BOD – Biological Oxygen Demand indicates the de
Slide 9: Conventional POME treatment practices
Conventional POME treatment practices − Typical palm oil mill process and POME generation points Fresh water Mill boiler Motive steam, 3 barg Sterilizer Digester (Direct Thresher and Clarification Drying injection) pressing Fresh fruit Hydrocyclone washwater Crude bunches palm oil Sterilizer condens
Slide 10: Stringent wastewater discharge standards
Stringent wastewater discharge standards Acceptable conditions of sewage discharge of standards A and B New sewage treatment system Parameter Unit Standard A B Drinking water (1) (2) (3) (4) (a) Temperature °C 40 40 BOD: 1–2 ppm (b) pH value – 6.0–9.0 5.5–9.0 (c) BOD5 at 20°C mg/L 20 50 (d) COD mg/L
Slide 11: Challenges of palm oil mill effluent
Challenges of palm oil mill effluent − A recap • Open ponding requires huge space • Methane (GHG) emissions to the atmosphere • Methane capture and reuse systems don’t offer a complete solution • No resource recovery • Issues with the discharge of treated effluent/re-use 27/10/2020 | © Alfa Laval 11
Slide 12: Alfa Laval POMEVap
Alfa Laval POMEVap 27/10/2020 | © Alfa Laval 12 | www.alfalaval.com
Slide 13: Alfa Laval POMEVap
Alfa Laval POMEVap − Forced circulation plate evaporator for treatment of palm oil mill effluent Based on AlfaFlash technology, POMEVap Single-effect efficiently separates effluent into: AlfaFlash plate evaporator • Water in the form of process condensate (~300–500 ppm BOD) • Solids in the form of c
Slide 14: POMEVap – Sustainable way of treating POME
POMEVap – Sustainable way of treating POME − Benefits of the Alfa Laval POMEVap Minimizes Resource Less space No methane mill water recovery emissions POMEVap requires consumption Separated oil only ≈ 300 m2 Condensate and sludge as can be re-used added income 27/10/2020 | © Alfa Laval 14 | www.alfa
Slide 15: Alfa Laval AlfaFlash
Alfa Laval AlfaFlash − Alfa Laval’s solution for fouling evaporation applications Probably the best evaporation technology AlfaFlash concept available for fouling applications • Forced circulation with suppressed boiling • Heats the liquid under pressure inside the heat exchanger • The heated liquid
Slide 16: AlfaFlash
AlfaFlash − Probably the best evaporation technology in the market for fouling applications • High liquid circulation rates → high turbulence AlfaFlash concept and high shear rate • Self-cleaning effect → cleaning/preventing fouling • Significantly improved CIP efficiency and maximum uptime V = 0 V
Slide 17: AlfaFlash for less fouling
AlfaFlash for less fouling − Better fouling resistance due to high shear rate and low viscosity Non-Newtonian Liquids 5000 Apparent viscosity (cP) 4000 3000 Conventional 2000 heat exchangers 1000 AlfaFlash 0 0 100 200 300 400 500 600 700 800 900 1000 Shear rate (1/s) 27/10/2020 | © Alfa Laval 17 | w
Slide 18: WideGap as AlfaFlash PHE – Wide Open for POME
WideGap as AlfaFlash PHE – Wide Open for POME − Handles liquids with suspended solids efficiently Alfa Laval WideGap heat exchanger • Optimal plate gap and pattern • Lower fouling rate, more uptime Contact in-line Free flow between contact lines Special non- clogging big studs port design 27/10/2020
Slide 19: AlfaFlash – Fouling performance from POME tests
AlfaFlash – Fouling performance from POME tests − Before and after: Trial on palm oil mill effluent Before cleaning After hot-water flushing (one week operation on POME) 27/10/2020 | © Alfa Laval 19 | www.alfalaval.com
Slide 20: POMEVap evaporator – How it works
POMEVap evaporator – How it works 27/10/2020 | © Alfa Laval 20 | www.alfalaval.com
Slide 21: POMEVap system
POMEVap system − Customized configurations to meet the mill’s needs Example – Triple-effect POMEVap system for mill with 30 tons of FFB/hr MOTIVE STEAM 2-3 Barg Effect-1 AlfaFlash Effect-2 AlfaFlash Effect-3 AlfaFlash AlfaCond Rec. Rec. Rec. Pump Pump Pump Cond. STEAM COND. Cond. Pump tank PROC. CON
Slide 22: POMEVap – Installed and commissioned
POMEVap – Installed and commissioned − For mill with 60/80 tons of FFB/hr Cyclone separation vessels and decanter Recirculation pumps 27/10/2020 | © Alfa Laval 22 | www.alfalaval.com
Slide 23: POMEVap – Installed and commissioned
POMEVap – Installed and commissioned − For mill with 60/80 tons of FFB/hr Visual impression of Concentrate POMEVap Mineral concentrated product disposal condensate water 27/10/2020 | © Alfa Laval 23 | www.alfalaval.com
Slide 24: Challenges faced by palm oil mills
Challenges faced by palm oil mills • Open ponding requires POMEVap system huge space Solved designed to tackle palm oil mill effluent • Methane (GHG) emission to atmosphere Solved • No resource recovery • Issues with discharge of treated effluent/re-use 27/10/2020 | © Alfa Laval 24 | www.alfalaval.c
Slide 25: POMEVap + decanter solution for oil recovery
POMEVap + decanter solution for oil recovery − Adding a decanter to the system to recover the oil Decanter Process Heavy condensate phase POMEVap POME (5% NOS + 1% oil) Concentrate Cake Light phase recovered oil (40–50% recovery) 27/10/2020 | © Alfa Laval 25 | www.alfalaval.com
Slide 26: POMEVap + decanter – Installed and commissioned
POMEVap + decanter – Installed and commissioned − 60/80 tons of FFB/hr Sample Oil content (%) Raw POME 1.30 Decanter feed 2.10 Heavy phase 0.55 Cake 0.55 Results: Soxhlet extraction Raw POME – Decanter feed – Heavy phase – Light phase 27/10/2020 | © Alfa Laval 26 | www.alfalaval.com
Slide 27: POMEVap + decanter solution for oil recovery
POMEVap + decanter solution for oil recovery − Combining decanter for oil recovery Value Unit Mill capacity (FFB/hr) 45 FFB tons/hr Mill capacity (FFB/year) 270,000 FFB tons/year* POME factor 0.60 – Total POME generated 162,000 tons/year Oil recovery from 1 to 0.5% 810 tons/year Oil price 650 USD/to
Slide 28: Challenges faced by palm oil mills
Challenges faced by palm oil mills • Open ponding requires POMEVap system huge space Solved designed to tackle palm oil mill effluent • Methane (GHG) emission to atmosphere Solved • No resource recovery Solved • Issues with discharge of treated effluent/re-use 27/10/2020 | © Alfa Laval 28 | www.alfa
Slide 29: Towards zero-liquid discharge in palm oil mills
Towards zero-liquid discharge in palm oil mills 27/10/2020 | © Alfa Laval 29 | www.alfalaval.com
Slide 30: Towards zero liquid discharge in palm oil mills
Towards zero liquid discharge in palm oil mills − Re-use of process condensate from POMEVap Fresh water Motive steam, 4 barg Mill boiler Sterilizer Digester (Direct Thresher and Clarification Drying injection) pressing Fresh fruit Hydrocyclone washwater, Crude bunches 4% of POME palm oil POME POME c
Slide 31: Alfa Laval SteamVap
Alfa Laval SteamVap − Alfa Laval evaporator for steam generation The Alfa Laval SteamVap is based on AlfaVap technology, a rising film plate evaporator Components 1 Evaporator PHE 1 Vapour separation vessel Typical 1 Frame with pumps SteamVap unit 1 Vapour outlet for discharging steam 27/10/2020 | ©
Slide 32: Towards zero liquid discharge in palm oil mills
Towards zero liquid discharge in palm oil mills − Key benefits to mill owners • A complete solution to solve POME issues • Reduced boiler feedwater consumption (additional income) • Recovery of oil from POME (additional income) • Sludge reuse as a by-product (additional income) • Based on proven, re
Slide 33: POMEVap system – compact design
POMEVap system – compact design − A comparison POMEVap system vs. Falling Film system 16 metres 8 metres POMEVap plate evaporator Shell-and-tube falling film evaporator 27/10/2020 | © Alfa Laval 33 | www.alfalaval.com
Slide 34: Focus on R&D
Focus on R&D To develop the POMEVap solution, Alfa Laval has tested the POME concentration using Alfa Laval’s evaporation test unit for an extended trial period (≈ 4 weeks) at customer mill sites in Malaysia 27/10/2020 | © Alfa Laval 34 | www.alfalaval.com
Slide 35: What can POMEVap do for you?
What can POMEVap do for you? − Input data needed for budgetary quote • Design inputs: Feed rate, feed concentration, feed temperature • Utility: Available steam temperature, ambient air temperature, available power (kW) • Oil content in the POME feed 27/10/2020 | © Alfa Laval 35 | www.alfalaval.com
Slide 36: Our evaporation system portfolio
Our evaporation system portfolio − Broad solutions for easy-to-handle and more challenging liquids AlfaVap AlfaCond AlfaFlash ViscoVap ConVap AlfaVap InLine FilmVap 27/10/2020 | © Alfa Laval 36 | www.alfalaval.com
Slide 37: Thanks for joining!
Thanks for joining! Do you want to get in touch? Reach out and send an e-mail to: amol.hukkerikar@alfalaval.com The presentation and the recording of this webinar will be sent out to the participants soon! For more information Alfa Laval POME Alfa Laval AlfaFlash management evaporation systems 27/10
Slide 38: Q&As
Q&As 27/10/2020 | © Alfa Laval 38 | www.alfalaval.com
Slide 39: www.alfalaval.com
www.alfalaval.com