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5.5 Kim Loong Methane Recovery for Onsite Utilisation Project at Kota Tinggi, Johor, Malaysia 5.5.1 Setting: Title: Kim Loong Methane Recovery for Onsite Utilisation Project at Kota Tinggi, Johor, Malaysia Country: Malaysia Location: 7 th Milestone Off Jalan Mawai, 81900 Kota Tinggi, Johor. Start date: 3 rd July 2006 Technology Industrial Waste keyword (s): Project type: Sectoral Scope 13: Waste Handling and Disposal 5.5.2 General description: Summary: The use of anaerobic ponds is the most common technology for wastewater treatment in the palm oil sector in Malaysia. Roughly 85% of the palm oil mills use this low-technology way of cleaning their organic rich wastewater. This project aims to reduce the methane emissions from the existing treatment of Palm Oil Mill Effluent (POME) from Kim Loong Palm Oil Mill at Kota Tinggi, Johor State of Malaysia. The methane emissions are being avoided by closing the existing anaerobic digester tanks to capture the methane for utilization in on-site heat and power generation. This project only covers the avoided methane emissions from closing the pond system. There is an ongoing expansion of the palm oil mill to incorporate facilities in downstream palm oil processing at the site. The expansion includes extraction of tocotrienols and other products from crude palm oil, and further recovery of oil from mesocarp fibre. The expansion will not increase the amount of effluent since the input of FFB will remain constant and the new production process does not produce wastewater. The new production facilities will increase the need for energy. The power needed will be 600 kW and 8-10 t steam per hour. With 300 working days of 24 hours this transforms into an electricity demand of 4,320 MWh and a steam demand of 195 TJ (with 10 t steam/hour and 2.702 GJ/t steam. The increase in power requirement will be produced through the methane captured from the waste water treatment. Aims: This project aims to reduce the methane emissions from the existing treatment of Palm Oil Mill Effluent (POME) from Kim Loong Palm Oil Mill at Kota Tinggi, Johor State of Malaysia. The methane emissions are being avoided by closing the existing anaerobic digester tanks to capture the methane for utilization in on-site heat and power generation. This project only covers the avoided methane emissions from closing the pond system. Operation time: The expected operational lifetime of the project is more than 20 years. Feasibility study: In the base case, the IRR of the project activity without financing 35
incentives from CDM will be 0.5 percent for 10 years of financial projection. However, with CDM financing, the IRR can be increased to 25 percent. A sensitivity analysis is conducted for another two other calculations i.e. “reduced capital cost by 25 percent” and “increased value of energy production by 25 percent”. However, the sensitivity analysis shows that the project IRR in all cases is unattractive without the extra income from sale of CERs. 5.5.3 Technical details: Technical details: The project will replace the existing open anaerobic systems (open digester tanks and lagoons) with well-proven closed, anaerobic contact digesters. This closed anaerobic digester technology is well-proven globally for managing high organic waste and commonly referred to as biogas or anaerobic digestion technologies. The POME will be distributed into the closed digesters at appropriately spaced inlets at the bottom and flows to the top in an upward direction. The upward motion of the POME influent will improve the mixing in the digesters. The organic matters in the wastewater are decomposed under anaerobic process. The decomposition process leads to the formation of biogas containing CH4 and CO2. The new anaerobic tank will be build from 10 mm mild steel with a stainless steel top cover plate. The existing tanks will get a 3 mm steel plate enforcement to prevent leakage and a new stainless steel cover plate. In order to prevent gas leakage from the enclosed digester tanks, an overflow tank will be constructed. The overflow tank is the device where biogas and anaerobic liquor are separated and the liquor can be discharged without escaping of the biogas. While the digested POME is channelled into aerobic ponds for further treatment, the captured biogas is pumped through a pipeline delivery system to the boiler for generating steam. A new biomass boiler delivering 52 t steam/hour is being built to replace an existing biomass boiler. The new boiler is designed to fire a mix of biogas, palm kernel shells, mezocarp fibre and empty fruit bunches. The residence time of the biogas in the boiler is long compared to a gas engine solution and that will secure that the methane will be fully oxidised into CO2. The environmental performance of the new boiler will be better than the existing boiler and will live up to all environmental requirements. The boiler will be equipped with an automated control system to improve performance and secure good combustion parameters at all times. The existing boiler is maintained for back up purposes. There is hardly any energy consumption of the project as it only includes pumping of the POME (which is also done in the baseline) and compression of the biogas before its is send to the boiler. The minimal project energy consumption is supplied from the biomass fired boiler and has thus no emissions of greenhouse 36
Page 1 and 2: COUNTRY REPORT MALAYSIA To: T@W ‘
Page 3 and 4: 5.5 Kim Loong Methane Recovery for
Page 5 and 6: 1.1 Malaysia Energy Policy Energy h
Page 7 and 8: 1.3 Malaysia Energy Consumption Fig
Page 9 and 10: In consonance with the growth of th
Page 11 and 12: 3 CDM in Malaysia 3.1 CDM Project D
Page 13 and 14: Criterion 2: Implementation of CDM
Page 15 and 16: to that, the technology transfer an
Page 17 and 18: 4 SET Opportunities Malaysia is wel
Page 19 and 20: Table 2: Examples of Potential Proj
Page 21 and 22: would be used for heat production a
Page 23 and 24: 5.1.3 Technical details: Technical
Page 25 and 26: 5.1.8 Photo library: Figure 1: Proj
Page 27 and 28: Aims: Operation time: Feasibility s
Page 29 and 30: GHG-emission reduction: “EAU, CER
Page 31 and 32: The project estimate the GHG reduct
Page 33 and 34: GHG emission reductions: ‘EAU, CE
Page 35 and 36: 5.4.3 Technical details: 5.4.4 Ener
Page 37: Type of organisation: Host Company
Page 41 and 42: “EAU, CER, ERU, AAU”: Methodolo
Page 43 and 44: Type of organisation: Project Parti
Page 45 and 46: iomass energy resources and non-ene
Page 47 and 48: In term of site selection, PTM will
Page 49 and 50: 6.3 Main Player and Target Groups f
Page 51 and 52: ANNEX 1 Project Developer CDM proje
Page 53: Project Developer Annex 3 PIN and C

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