KKEK 4281 DESIGN PROJECT FAST PYROLYSIS OF EMPTY FRUIT BUNCH TO PRODUCE INDUSTRIAL GRADE BIOFUELS AND METHANE

GAS

FEASIBILITY REPORT GROUP 5

NAME KIM NING SIN MOHAMMAD RUZAINIE BIN MOHAMMAD ISA NURSHAKIRIN BINTI HAZIM CHAN TAN XUAN MIN NURUL NABILAH BINTI OTHMAN MATRIC NO. KEK 100014 KEK 100027 KEK 100046 KEK 100058 KEK 090043

FACILITATOR: DR. CHE ROSMANI BINTI CHE HASSAN

1. Introduction
The plant used empty palm fruit bunch with a capacity of 330000 tons per year and undergo pyrolysis process and post process to produce industrial grade biofuels. In the post processing, carbon dioxide is capture and produce methane gas at a rate of 12375 tons per year. The upgraded bio oil is undergoing using high pressure thermal treatment and hydrodeoxygenation to improve the quality of bio oil. Each year, the plant is able to produce 175725 tons per year of industrial grade biofuels.

2. Different Process Route

Empty Fruit Bunch (EFB) conversion technologies to biofuels can be classified into two broad categories: Thermo-chemical conversion and biological conversion. In thermo-chemical conversion, the components of EFB are heated with high temperature in the absence of oxygen. Among the conversion process that are grouped under the thermo-chemical conversion are pyrolysis, gasification and liquefaction. The product obtained from the thermo-chemical conversion depends on the conversion process used. [1] On the other hand, biological conversion involves the usage of the biological living things such as yeast and bacteria in the conversion process of components of EFB to biofuels. The examples of conversion process in biological conversion are fermentation and anaerobic digestion. The main product obtained from the biological conversion is bioethanol. [1] There are three conversion processes that are considered in choosing the route to convert EFB to biofuels. The three conversion processes are pyrolysis, gasification and fermentation. The main product yield by pyrolysis, gasification and fermentation of EFB are bio-oil, syngas and hydrous ethanol respectively. These products can be further refined to produce biofuels that can be used as transportation fuels and many more. Based on extensive literature review, the process flow charts and the summary of pyrolysis, gasification and fermentation conversion process are shown in Appendix 1 Figure 2.1 and listed in Table 2.1 Table 2.1: Summary of conversion processes [1, 3] Pyrolysis
Main Product

Fermentation Ethanol The fermenting organisms

Gasification Syngas Reduced biomass

Bio-oil Low capital

Advantage

and operating cost Simple preparation of EFB

do not have to be purchased because they regenerate themselves.

transportation costs

Disadvantage

Involves the use of microbes or enzymes which require specific climate conditions Limit the productivity due to biological conversion.

High capital cost Need effective cleaning methods which are complicated and expensive Complex process

2.1 Simple Process Description of Pyrolysis and Post Processing of Bio Oil
After critical consideration on information obtained in Table 2.1, the pyrolysis process is selected as the best EFB conversion process. First the EFB will pretreat using chemical and thermal treatment to improve pyrolysis process. Then the bio-oil obtained from the pyrolysis of EFB is refined to upgrade the quality of bio-oil produced using high pressure thermal treatment and hydrodeoxygenation. In addition, the refinery of bio-oil also produced methane gas as by product by capture the CO2 and reacted with H2. The charcoal produce from pyrolysis process can be recycled back to furnace for energy recovery, while the aqueous phase of bio oil is undergo hydrolysis process to form H2 to recycle back to plant for processing. The waste water produced will treated using anaerobic digestion method to remove the organic matter in the water and reuse back in hydrolysis process. The overall production process of bio-oil is shown in Figure 2.2.

Figure 2.1: Overall production process of bio-oil The preliminary process route of the plant is attached on Appendix 1 figure 2.2

3. Plant Location
The plant is set on Tanjung Langsat Industrial Area, Pasir Gudang, Johor due to several reason:-

Site for EFB Pyrolysis Plant

Figure 3.1: Bird Eye View of the Plant Location [5] It has easy access to raw materials since there have about 6 palm oil mill in the range of 10km which able to provide about 3.2 million tons per annum.[12] The site near to several major city in Johor such as Pasir Gudang (5 min journey), Masai (5 min journey), Johor Bahru (15 min journey) and Kota Tinggi, the coming administration city in Johor (30 min journey) which provide numerous labor force, good transportation system including two ports, airport and complete road system. The plant also can expand the business to Singapore in future. Since the site is an industrial park, thus the government provides complete and stable utilities supply in that area and the price of the land is about RM 20/ft2 which is reasonable. [10] Furthermore the industrial park locate numerous industrial plant and power plant which use industrial diesel for energy production, so the plant can target them as potential customer, plus the oil can export to Singapore. Last but not least, there have no opposition for onsite community as the place is reserved for industrialization and support by local government. [6] The raw materials can easily transport by truck and the plant is able to build a pipeline system to transfer the product to port storage tank and direct transfer to other industry plant.

4. Availability of raw materials

The raw materials used for bio oil and methane gas is empty palm fruit bunch which abundant in Malaysia. The availability of biomass from palm oil industry in Malaysia is assessed by using official data from Malaysia Palm Oil Board (MPOB). From the Appendix 1 figure 4.1, it can be seen that the EFB production hit 15 millions tons per annum which is sufficienct for the plant production as the plant only required less than 1% of EFB production in Malaysia. It is assumed that EFB is fully available as it is currently brought back by plantations for disposal or dumped in piles and landfills near the mills. In the other hand, the reason behind the plant located in Johor is due to Johor state had high distribution of oil palm planted area which up to 687906 hectares which up to 30% of plantation area in Penisula Malaysia as can observe form Appendix 1 figure 4.2. In addition, the plant situated nearby 6 palm oil mills which produce adequate raw materials for the pyrolysis plant.

5. Market Survey
5.1 : Analysis of Product (Bio oil)
Pyrolysis oil can be used as a substitute for heating oil and industrial diesel which used in several industrial applications such as boiler, furnaces, hot water generators, hot air generators, thermic fluid heater and etc. Bio oil is produce in country which has extensive reserves of low cost biomass such as Brazil, Canada and South Africa by pyrolysis sugarcane bagasse, forest waste and agriculture waste. Below show a table of supply of bio oil from 2008-2012:Table 5.1.1: Pyrolysis oil supply from 2008 to 2012[7] Year 2008 Pyrolysis Oil Supply (000 tons) 240 2009 940 2010 2222 2011 3644 2012 5000

Table 5.1.2: Demand of heavy fuel oil for Malaysia is shown:-

387 petajoules = 130Gt of bio oil

5.2 : Demand of Biofuels in Industrial Plant

Using the data above, it seems the demand of the HFO increase each year, thus the bio oil is expected to have high demand in future since it is cheaper and environmental friendly compare to traditional fuels. The product is expected to fully replace the HFO, thus it found it still had 8 million tons of bio oil to fill up the Malaysia market. Although bio oil has a lower heating values compare to HFO, but it show a cleaner and cheaper alternative. It should be noted that Genting Bio Oil is cooperate with Canadas Dynamotive Energy Systems to build the first pyrolysis plant in Malaysia.[8] The plant situated in Pasir Gudang, Johor will had a high demand of pyrolysis oil because nearby got various industrial plants such as TITAN, VAW Aluminum, Spectrum Food and etc. From the Appendix 1 figure 5.1.1, it can be seen that the potential of biofuels is enormous in the future and the plant is able to export the biofuels to regional area such as China and India which will out as one of the strong nation in future as the biofuels demand increase 1EJ (1X1018 J) per year. Furthermore, the upgraded bio oil can further improve it quality to form consumer grade oil which has higher market values.

5.3 : Analysis of methane gas

Methane gas produced as byproduct by methanation of CO2 which also can be used important energy source since it can produce liquefied natural gas (LNG) which provides an alternative clean source of energy to industrial. From Appendix 1 figure 5.2.1 it can be seen that the demand of methane gas increase in long term up to 24 million tons of methane gas is used per year. Besides that, methane gas can be feed-stocks to produce methanol which forms various useful products such as fuels additive, olefins, paints and etc.

5.4 : Price of Fossil Fuels

The price range of pyrolysis oil is highly affected by the crude oil price is shown in Appendix 1 figure 5.3.1. The price of crude oil and HFO increase in long term due to its scarcity and high demand, thus pyrolysis oil had the advantage to compete in market due to its cheapness and environmental friendly. Government is highly support industrial using clean fuel as they planned to reduce carbon footprint by 40% by 2020 and would like to give incentive and deferred tax for company that support this act. The price of heavy fuel oil is in range of RM1.95-2.15 per liter with subsidies while the price of upgraded pyrolysis oil is expected in range of RM1.5 per liter without any subsidies. [9] This shown that the bio oil had price advantage when compete with HFO in the market.

5.5 : Analysis of raw materials (EFB)

There have several possible biomass feed-stocks for pyrolysis process to produce biofuels such as empty fruit bunch, wood chips, rice husk and etc. From Appendix 1 table 5.4.1, it can be seen that empty palm fruit bunch is the best raw materials for pyrolysis process due to high availability in Malaysia and cheap price. Although the conversion of bio oil is lower compare to wood chips, but the price is 10 times cheaper which highly reduce the operating cost in long term. From section 4, it shown that the availability of EFB in Malaysia is secure and is projected to increase in future due to population increase and increase demand of vegetable oil. EFB feedstock is easy to obtain in Malaysia and in long term, the price of EFB do not fluctuated because of huge volume and low demand of the materials.

6. Preliminary of Economics Analysis

A simple evaluation of cost and benefits of the proposed project of the construction of 9000 metric tons per year of upgraded bio oil should be done to analyze the potential of the proposed project based on research and investigations.

6.1: Total Capital Investment

Total capital investment is sum include land, fixed capital investment and working capital investment. Some assumptions should be done due to lack of information.

6.2: Land Cost Estimation

The location proposed site (Tanjung Langsat) had some distance from urban area (Pasir Gudang & Johor Bahru) where 6 palm oil estate and several palm oil mills are situated. The land price is approximately RM20/ft2. [10] It is estimated that the land area for the proposed plant is about 10 acre which cost about RM108900027. Currently at this capacity of the plant which only required about 4-5 acre, however the plant allocated additional of 5 acre of land in order to increase the plant size to satisfy the world demand.

6.3: Fixed Capital Investment

Fixed capital investment is total amount of money required to spend before the plant commission. The plant is divided into 3 main parts:1) Pretreatment of empty palm fruit bunch 2) Pyrolysis of empty fruit bunch 3) Post processing of bio oil a) High pressure thermal treatment of bio oil b) Hydrodeoxygenation of treated bio oil c) Methanation of carbon dioxide d) Hydrolysis of aqueous phase bio oil The plant is estimated used various unit operators in producing the biofuels. Appendix 2 table 6.1 will show that the total usage of equipment required and table 6.2 estimated cost of each unit operation. The cost of unit operation is estimated using literature from PNNL-18284 from U.S. Department of Energy and the scale factor is 0.1 while the inflation rate [16] is based on the mean of inflation rate obtained from Department of Statistics Malaysia. The cumulative inflation rate for 7 years extend is about 15.9% [15]

Estimation of Equipment Cost Land Cost Estimation of Operating Cost

RM 211657114 RM 108900027.6 RM 164528002.8

Refer Appendix 2 Table 6.4 Refer Appendix 2 Table 6.5

6.4 : Sales Revenue

The price of industrial grade biofuels is set around RM 1742.16 per tons in Malaysia while the price of methane gas is RM 1742.16 per tons. The production rate of product and consumptions rate of raw materials can be obtained in Appendix 2 table 6.6. Thus the total annual sales of product and by product is about RM 328183762.5 not including the production of hydrogen gas since it is use in the post processing of bio oil.

Breakeven Period Graph

3,000,000,000.00 2,500,000,000.00 Breakeven period without interest Breakeven period with compound interest

2,000,000,000.00

1,500,000,000.00 RM 1,000,000,000.00 500,000,000.00

0.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 (500,000,000.00)

Figure 6.3: Payback Period Graph

6.5: Rate of return analysis

The minimum rate of return (ROR) is 10% to obtain financial support from financial institute. Since the project can achieved about 25% of return, thus it is considered as feasible and profitable for investment. The payback period with 5% interest required about 6 years including 2 years of plant construction and commissioning.

6.6: Taxation
The plant is expected to obtain pioneer status which has the advantage to have total exemption from income tax for 5 years as the exempt income are credited to the exempt account from which exempt dividends are distributed to the shareholder of the company. The plant is expected to improve the quality of bio oil to consumer grade which will again grant the pioneer status for a decade.

7. Safety Consideration
Safety is an important aspect in the industrial which require constant attention from management to reduce the risk of wide range of threats and mitigating the effects of accidents. Several safety efforts conduct by management will protect the community and company employees while keeping the plant operational and profitable. Safety precautions should be performs to minimize the risk of the plant. Some example of safety consideration is personal protective equipment (PPE), work permit, appropriate labeling, safety data sheet and maintenance. Other than that, the process safety of pretreatment, pyrolysis and post processing are reinforced with safeguard to strengthen safety. (For details process safety, process safety is elaborated in Appendix 3 table 1) Besides that, the plant also designed an evacuation route plan based on the plant layout (refer in Appendix 3 figure 1) to ensure that the entire worker can evacuate towards safety in the shortest time to minimize the consequences of the health and safety of people in the event of emergency based on OSHA guidelines. From the Appendix, it shown that the fire extinguisher, alarm and first aid can be easily accessed to all people. The escape route of the plant is based on In addition,

safety inspection will be held from time to time in order to make sure that the safety equipment such as alarm and fire extinguisher can be operated at all time. All emergency number is show in notice board in plant and provided to workers. An emergency response team is available so that they manage safety operation in the plant. From Appendix 3 figure 2, it shown the wind pattern of the of plant site which is important when fire and leakage break out. The emergency gather site should be at the upwind (north side of the plant) to ensure the safety of worker. In the case of emergency, the worker should train to perform emergency shutdown to avoid critical condition on unit operator such as reactor and heat exchanger as unattended unit will increase the level of danger. The MSDS of the chemical that used should provide to the entire operator to let them understand the correct way to handle the chemical to minimize risk. Material safety data sheet (MSDS) is a document which provides people with procedure for handling in a safe manner which includes information such as physical data, toxicity, first aid, reactivity, storage, protective equipment and health effect. The MSDS of chemical that used regular is shown is Appendix 4.

8. Environmental Consideration
The plant produce liquid and gas product and had identify the waste which will implement suitable action to prevent the waste to destroy the environment:-

8.1: Solid Waste Management

The solid wastes include sludge, garbage and discard unusable materials. For domestic solid waste, it just required to dispose on the designated site for collection by the city council. For material coming from industrial process, the waste should be treated more cautiously. It should be divided into hazardous and non-hazardous. For hazardous material such as activated sludge should be classify as schedule waste which will be deal by professional team. For used catalyst, it can be reactivated by using high temperature or polishing reactor. For unusable catalyst, it will also consider as schedule waste and collect by outsource company to properly treat the waste.

8.2: Air pollution control

The plant produces syngas (CO, H2 & CH4) which is a group of greenhouse gases and dangerous to human. The gas is used as one of the fuel sources to burn up the furnace. In the post processing of the bio oil, it produces a high concentration of CO2 (around 96%). The CO2 is capture using pressure swing adsorption and react with hydrogen gas using methanation reaction to produce a higher value product. The plant also includes several instruments such as gas detector and pressure detector to monitor the gas to prevent leakage. There may be ash flying ash cause by the furnace thus a filter installed to filter the ash before allow the smoke to release to atmosphere. The emission of the plant is followed the regulation of Department of Environmental Malaysia and detail of emission is shown is Appendix 5 table 1.

8.3: Wastewater treatment

In the post processing of bio oil, the hydrodeoxygenation produce wastewater contains about 2% of organic matter which can be treated by anaerobic digestion of microorganisms in batch system. The treated water should be tested and reused in the process to reduce utility cost. All the waste that disposes to environment should achieve the Department of Environment regulation which shown in Appendix 5 figure 1 and 2 to prevent pollution issue and fine by DOE. The details of each type of waste, source and treatment method are summarize in Appendix 5 table 1

8.4: Noise and light pollution management

The noise pollution is allow to be on around 30-60dB[22] in order to avoid disturbance to other community around the plant site by using light and sound absorbed materials wherever is possible and installed intelligently designed, low glare fixtures for outdoor lights to reduce light intensity and place motion sensor on essentials outdoor lamps to reduce the time for expose light and lastly replace the conventional high energy bulbs with efficient outdoor LED floodlights to reduce glare and save the energy consumptions of the plant.

9. Novelty of the Chosen Route

Although pyrolysis process is an ancient process to produce charcoal, but today it could further improve to produce fuels to run the engine. To improve the pyrolysis process, the charcoal produce in pyrolysis process is reuse in furnace to reduce the

energy consumptions of the plant. The produced bio oil also upgrades to improve the quality (higher heating values, low sulfur content & low moist content) to increase the market values. Mostly the bio oil use hydrotreating to reduce the oxygen components in the bio oil which using enormous amount of hydrogen, but in this design project, the oil is pretreated using high pressure thermal treatment (HPTT) to reduce the hydrogen consumptions about 50% during hydrodeoxygenation process. The plant also improve it efficiency by hydrolysis the aqueous phase of bio oil to hydrogen to further reduce hydrogen consumptions and also used the captured carbon dioxide to produce methane gas to reduce carbon emission and improve plant revenue. In the journal, the hydrodeoygenation process proposed 5 packed reactor but in this design project, the team is try to reduce the reactor number to 3 by improving the conversion and efficiency of process since the bio oil had been treated by HPTT process.

10.Comparisons with other possible routes

From the section 2, it has been shown that the advantage and disadvantage of the different process route using pyrolysis, fermentation and gasification process. The team decides pyrolysis as best method due to following reason:a) The bio oil produced have an marketing advantage compare to other product like ethanol (fermentation) and syngas (gasification) as bio oil easily transport from site to site, not like syngas which required pressurized tank to transport or build a special pipeline to transfer the product. For ethanol, it has weak market demand because ethanol production is high in the world; in addition the demand of ethanol in Malaysia is lower compared to bio oil. b) For fermentation process, it has a major disadvantage as it used microbes to produce ethanol which easily fluctuated due to inconsistent of microbes metabolisms as this will highly affected the production rate of the products. c) The technology for pyrolysis process is available as it is a developed process in the world and it will form a new energy revolution for the world as it used empty fruit bunch which is abundant in Malaysia as raw materials. For bio oil, it required to upgrade by various method to improve the quality of the product to increase the product market value as the bio oil has high oxygen content. There have several post processing methods such as

hydrodeoxygenation, high pressure thermal treatment, esterification, steam reforming, emulsification and catalytic cracking. Table 10.1: Comparison between hydrodeoxygenation and catalytic process Method Hydrodeoxygena -tion Advantages

Disadvantages

Remove high content of oxygen components Improve thermal and chemical stability of the oil Can produced consumer grade fuels which has higher value compare to hydrodeoxygenation bio oil

High cost

Catalytic cracking

Easily affected by calcination temperature High energy required as high temperature is needed

The team chooses combination of hydrodeoxygenation and high pressure thermal treatment as it is one of the prestigious method to improve the bio oil by reducing the oxygen content by replacing it with hydrogen. In the other hand, the catalytic cracking is an energy intensive process which not practical in industrial scale. Since hydrodeoxygenation process required high cost due to high consumptions of hydrogen gas, thus high pressure thermal treatment is used to reduce the hydrogen consumptions up to 50% to improve the plant revenue.

11.Reference
1. Geng A., Conversion of Oil Palm Empty Fruit Bunch to Biofuels. Liquid, Gaseous and Solid Biofuels - Conversion Techniques, 2013: 479-490. 2. McKendry P., Energy production from biomass (part 2): conversion technologies. Bioresource Technology, 2002; 83: 4754. 3. Thorp B. A., Key Metric Comparison of Five Cellulosic Biofuel Pathways. Bioenergy Technologies Quarterly, 2010: 23-30. 4. Jones S. B., Production of Gasoline and Diesel from Biomass via Fast Pyrolysis, Hydrotreating and Hydrocracking: A Design Case. Pacific Northwest National Laboratory, 2009. 5. Bird eye view of plant location, Retrieved from Google Earth: http://www.google.com/earth/ 6. Information regards industrial development, Retrieved from Malaysia Investment Development Authority (MIDA) website: http://www.mida.gov.my 7. Doug Bradley, European Market Study for Bio Oil (Pyrolysis Oil), December 15, 2006; 4 8. Corrinne Ling, Genting Group Unveils Malaysias First Commercially Produced Bio Oil using Breakthrough Technology, 21 August 2005: 1-3 9. Price of fuel and bio oil, (23 Sept 2013) Retrieved from Malaysia Investment Development Authority MIDA: http://www.mida.gov.my/env3/index.php?page=gas-and-fuel-costs 10. Price of land in Tanjung Langsat, (2013) Retrieved from Tansact Properties: http://www.transact.com.my/view.php?id=25172 11. McKendry P., Energy production from biomass (part 2): conversion technologies. Bioresource Technology, 2002; 83: 4754. 12. Quantity of empty palm fruit bunch, Retrieved from Asia Biomass Office: http://www.asiabiomass.jp/english/topics/1001_03.html 13. Demand of methane gas in Malaysia (2010), Retrieved from Gas Malaysia Sdn. Bhd.:http://www.gasmalaysia.com/about_gas/malaysian_ng_demand.htm

14. Price of crude oil in world (2013), Retrieved from Index Mundi: http://www.indexmundi.com/commodities/?commodity=crude-oil-brent&months=3 00 15. Inflation in Malaysia in past 5 year (2013), Retrieved from Trading Economics: http://www.tradingeconomics.com/malaysia/inflation-cpi 16. SB Jones, C Valkenburg, CW Walton, DC Elliott, JE Holladay, DJ stevens, C Kinchin & S Czernik, Production of Gasoline and Diesel from Biomass via Fast Pyrolysis, Hydrotreating and Hydrocracking: A Design Case, February 2009; 1-38 17. M. Ringer, V. Putsche & J. Scahill, Large Scale Pyrolysis Oil Production: A Technology Assessment and Economic Analysis, November 2006; 38-93 18. Muhammad L. Jahirul, Muhammad G. Rasul, Ashfaque Ahmad Chowdhury & Nanjappa Ashwath, Biofuels Production through Biomass Pyrolysis: A Technological Review, 23 November 2012; 23-50 19. Murni M. Ahmad. M Fitrir R. Nordin & M. Tazli Azizan (2010) Upgrading of Bio Oil into High Value Hydrocarbon via Hydrodeoxygenation. American Journal of Applied Science 7 (6): 746-755 20. Ferran de Miguel Mercader, Pyrolysis Oil upgrading for Co-Processing in Standard Refinery Units (2010); 34-57 21. Environmetal Requirement the Eleventh Edition: A Guide For Investors by Department of Environment, Ministry of Natural Resources and Environment October 2010 22. Statistically about noise pollution, UNESCO Module 18: Noise Pollution, Retreived from UNESCO, 2012 at http://www.unesco.org/education/educprog/ste/pdf_files/sourcebook/module18.p df 23. Wind pattern in Johor, Retrieved from Windfinder at 2013 at http://www.windfinder.com/weather-maps/forecast#7/2.526/103.667

12.Appendix 1

Figure 2.1: Process flow charts of conversion process of EFB to main products [11]

Figure 4.1: production of palm oil biomass in Malaysia

Figure 4.2: Distribution of palm oil estate in Malaysia [12]

Figure 5.1.1: The future potential of biofuels is 50 years time

Figure 5.2.1: Demand of methane gas in Malaysia from 1990 to 2009 [13]

Figure 5.3.1: Price range of crude oil in 5 years time [14]

Table 5.4.1: Availability of raw materials and the price Raw Materials Empty fruit bunch Conversion 58% bio oil, 30% bio char, 12% syngas Availability 15 million tons/year Price/tons RM5-10

Wood chips

75% bio oil, 10% bio char, 15% syngas

2.5 million tons/year

RM50-150

Waste Tire

45% bio oil, 30% bio char, 25% syngas

60000 tons/year

RM100-150

13.Appendix 2
Table 6.1: Estimated total equipment required to purchase Pretreatment process Reactor Separator Distillation Column Compressor Cyclone Mixer Pump Sand heater Filter Crusher Screen Dryer Demister Heater PSA 1 1 1 1 4 1 1 1 4 1 1 1 2 1 1 1 1 1 Pyrolysis process 1 Hydrocracking process 6 1 Total

7 1 1 3 2 2 5 1 2 1 1 1 1 4 1

Figure 6.2: Inflation rate of Malaysia from 2007 to 2012 [15]

Table 6.3: Estimation Cost of unit operation that required in the plant Cost from literiture at 2007 8951542 Scale Factor Inflation Cost Estimated Cost

Equipment

Quantity

Total

Pyrolysis reactor Plug flow reactor Packed bed reactor Pressure swing adsorption Separator Distillation Column

0.1

16%

1038378.872

1038378.872

2125929

0.1

16%

246607.764

246607.764

19852131

0.1

16%

2302847.196

11514235.98

4838004

0.1

16%

561208.464

561208.464

1663113 435862

0.1 0.1

16% 16%

192921.108 50559.992

1 1

192921.108 50559.992

Compressor Cyclone Mixer Pump Sand heater Crusher Dryer Demister Heater Total

186181 40000 60000 185908 20000 20000 48011 675313 3991092

0.1 0.1 0.5 0.1 0.5 0.1 0.1 0.1 0.1

16% 16% 16% 16% 16% 16% 16% 16% 16%

21596.996 4640 34800 21565.328 11600 2320 5569.276 78336.308 462966.672

3 2 2 5 1 1 1 1 4

64790.988 9280 69600 107826.64 11600 2320 5569.276 78336.308 1851866.688 15805102.08

Currency exchange of 1USD=RM 3.15 Total 49786071.55

Table 6.4: Estimation Cost for Capital Investment % Delivery-equipment Estimated Cost Cost

Components

Direct Cost Purchased equipment (including delivering and fabrication) Installation equipment Instrumentation & controls Piping Electrical system 100 39 26 31 10 49743152.52 19399829.48 12933219.66 15420377.28 4974315.252

Insulation Building Yard improvement Service facilities Total Direct Cost Indirect Cost Engineering & supervision Construction expenses Total Indirect Cost Total direct and indirect cost

2 29 12 35

994863.0504 14425514.23 5969178.302 17410103.38 141270553.2

32 34

15917808.81 16912671.86 32830480.66 174101033.8

Contractors' fee Project Contingency

5 D+I 15 D+I

2487157.626 7461472.878

Fixed Capital Investment Working Capital Investment Total Capital Investment 15% FCI

184049664.3 27607449.65 211657114

Table 6.5: Estimation of production and consumptions of raw materials and products

Materials/Products EFB Hydrogen gas Hydrogen gas Bio oil Methane gas Total

Unit Price (RM/tons) 8 4217 4217 1742.6 591.66

Capacity (tons/yr) 330000 19255.645 2293.3 175725 12375

Cost (RM/yr) 2640000 81201054.97

Revenue (RM/yr)

9670846.1 306218385 21965377.5 74170208.87 328183762.5

Table 6.6: Estimation of Operating Cost Components Variable Costs Raw materials Refer appendix 2 table 6.5 10% of raw materials cost 74170208.87 Percentages (%) Cost

Miscellaneous materials Utilities Steam

7417020.887

5% of raw materials cost 5% of raw materials cost 5% of raw materials cost

3708510.444

Water

370851.0444

Electricity Total Variable Cost

3708510.444 89375101.69

Fixed Costs Maintenance Operating labor Supervision 20% operating labor 20% operating labor 15% FCI 1% FCI 2% FCI 1% FCI 5% FCI 29657250 5931450

Plant overheads Capital charges Insurance Interest rates Royalties Total Fixed Cost Direct Production Cost

5931450 27607449.65 1840496.643 3680993.286 1840496.643 76489586.22 165864687.9

Sales expense General Overhead Research and Development Annual Production Cost 20% of direct production cost 33172937.58

199037625.5

Table 6.7: Cash Flow for Plant for 25 Years Year Cash Flow 0 -320557142 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 0 0 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 Present Worth -320557141.6 0 0 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 129146137 Cumulative PW -320557141.6 -320557141.6 -320557141.6 -191411004.6 -62264867.57 66881269.43 196027406.4 325173543.4 454319680.4 583465817.4 712611954.4 841758091.4 970904228.4 1100050365 1229196502 1358342639 1487488776 1616634913 1745781050 1874927187 2004073324 5% Interest rate Present Worth 1 -320557141.6 0.9524 0.907 0.8638 0.8227 0.7835 0.7462 0.7107 0.6768 0.6446 0.6139 0.5847 0.5568 0.5303 0.5051 0.481 0.4581 0.4363 0.4155 0.3957 0.3769 0 0 111556433.1 106248526.9 101185998.3 96368847.43 91784159.57 87406105.52 83247599.91 79282813.5 75511746.3 71908569.08 68486196.45 65231713.8 62119291.9 59161845.36 56346459.57 53660219.92 51103126.41 48675179.04 Cumulative PW -320557141.6 -320557141.6 -320557141.6 -209000708.4 -102752181.5 -1566183.183 94802664.25 186586823.8 273992929.3 357240529.2 436523342.7 512035089.1 583943658.1 652429854.6 717661568.4 779780860.3 838942705.6 895289165.2 948949385.1 1000052512 1048727691

21 22 23 24 25

129146137 129146137 129146137 129146137 129146137

129146137 129146137 129146137 129146137 129146137

2133219461 2262365598 2391511735 2520657872 2649804009

0.3589 0.3418 0.3256 0.3101 0.2953

46350548.57 44142149.63 42049982.21 40048217.08 38136854.26

1095078239 1139220389 1181270371 1221318588 1259455442

14.Appendix 3
Unit Function operation Grinding machine Used to grind EFB Hazard Causes Possible consequences

Detection

Safeguard

Handling sharpening tools when cleaning, polishing and buffing surfaces.

Fingers are caught between grinder Entanglement of hair or clothing in rotating parts of the grinding machine Sparks formed by the grinding action

Injured or death Rubbing noises

Drying machine

EFB should be totally dried To breakdown the lignin

High temperature of steam High corrosivity

Superheated of steam

Damage human body Corrode pipes

Personal protection equipment (PPE) should be applied includes safety glass, hand gloves, cover shoes and lab coat. Check the grinding wheels Sound levels from machines can be reduced with barriers PPE should be applied Keep drying machine in good working order PPE should be applied Clean up spills immediately Do not store near combustible materials Keep it in well ventilation area

Mixer

High concentration of NaOH

Chemical burns Permanent injury blindness

Pyrolysis reactor

To paralyze the EFB

High temperature

Loss of cooling Incorrect feed composition

Hot surfaces of the reactor Thermal shocks

Temperature controller

Pyrolysis furnace

To combust the syngas to produce energy Syngas is produced from furnace

Furnace tampering with combustion safety control

Loss control of furnace safety control

Fire Explosion

Proper maintenance should be done regularly

Leakage of flammable syngas

Inconsistent maintenance Pipe corrosion

Fire Explosion

Lead detection system

Insure pips is inert

Plug flow reactor

To reduce of the oxygen in the bio oil CO is produced

High temperature

Loss of cooling Incorrect feed composition

Hot surfaces of the reactor Thermal shocks

Temperature controller

Leakage of CO

Pipe corrosion

Dizziness

Online chromatogra ph Lead detection system

Monitoring of composition

H2 is produced

Leakage of H2

Pipe corrosion

Can be ignite easily causing fire and explosion

Keep the agitator substances away from the hydrogen storing area Adequate ventilation Safe discharge of the exhaust

Packed bed reactor

To reduce the oxygen content Biofuel is produced

High temperature

Loss of cooling Incorrect feed composition

Fire Explosion

Temperature controller

Maintenance should be done regularly

Leakage of biofuel

Fail in transferring the biofuel

Flammable liquid trigger fire and explosion Table 1: HAZOP analysis of the plant

Keep all the pipes tight Keep all the agitators away from biofuel

Expansion

Steam Generator G a t e 1 Refinery Area Product Storage

Raw Material Storage

Pretreatment Area

Char Storage

Pyrolysis Area Chemical Storage

Canteen

Rest Room

Office

TNB

Main Gate Assembly Point Legend:

Guard House Fire Extinguisher

Figure 1: Emergency evacuation plan

Hose Reel

Figure 2: The wind pattern of the plant site [23]

15.Appendix 4: MSDS for hydrogen, methane & bio oil

Section 1 2 3 4 5 6 7 8 9 10 11 12 Content Product Name Physical and Chemical Properties Composition, Information on Ingredients Hazard Identification First Aid Measures Fire Fighting Measures Accidental Release Measure Handling and Storage Exposure Controls, Personal Protection Stability and Reactivity Toxicological Information Disposal Considerations

Hydrogen 1. Product Name Chemical Name : Hydrogen (H2) Synonyms : None UN Number : 1049 Use : Combustion, reducing atmospheres (e.g. steel industry), hydrogenation of oils and fats, laboratory as a carrier gas.

2. Physical and Chemical Properties Formula Chemical structure Molecular weight UN Number H2 H-H 2.0159 UN1049 (gas) UN1966 (liquid)

Appearance Density(gas) Melting point Boiling point Solubility in water

Colourless and odorless gas at room temperature 0.08988gL-1 (at -253 oC) -259.35 oC -.252.88 oC (at 1atm) 0.0214 cm3/g (0oC, 1 atm)

Auto ignition temperature

500 271 oC

3. Composition, Information on Ingredients CHEMICA L NAME CAS # Mole % EXPOSURE LIMITS IN AIR ACGIH-TLV OSHA-PEL NIOSH OTHER IDLH TWA STEL TWA STEL ppm ppm ppm ppm ppm ppm There are no specific exposure limits for Hydrogen. Hydrogen is a simple asphyxiant (SA). Oxygen levels should be maintained above 19.5% None of the trace impurities of this gas contribute significantly to the hazards associated with the product. All hazard information pertinent to this product has been provided in this Material Safety Data Sheet, per the requirements of the Federal Occupational Safety and Health Administration Standard (29 CFR 1910.1200), U.S. State equivalent Standards and Canadian Workplace Hazardous Materials Identification System Standards (CPR 4).

Hydrogen

1333-74-0 99.99%

Maximum Impurities

< 1% (100 ppm)

4. Hazard Identification Dangerous Goods Class and Subsidiary Risk : 2.1 HSNO Classification : 2.1.1A Hazard Statement : Extremely flammable gas. Explosive; fire, blast or projection hazard.

Precautionary Statements Read before label before use. Read material safety data sheet before use. Keep away from heat, sparks, open flames and hot surface. No smoking. Leaking gas fire: Do not extinguish, unless leak can be stopped safely. Eliminate all ignition sources if safe to do so. Store in a well ventilated place. Do not subject to any rough handling (grinding/shock/friction/banging). Explosion risk in case of fire. Fight fire with normal precautions from a reasonable distance. Take precautionary measures against static discharges. Wear protective gloves and eye protection.

5. First Aid Measures Health Effects Acute Swallowed: Not applicable to gases Eye: Not irritating to the eye Skin: Not irritating to the skin Inhaled: Hydrogen is non-toxic; by diluting the oxygen concentration in air below the level necessary to support life; it can act as an asphyxiant. Effects of oxygen deficiency are: 16%: breathing and pulse rate increased, impaired thinking and attention, reduced coordination; 14%: Abnormal fatigue upon exertion, emotional upset, faulty coordination, poor judgement; 12.5%: Very poor judgement and coordination, impaired respiration that can cause permanent hearing damage, nausea and vomiting; below 10%: Inability to perform various movements, loss of consciousness, convulsions, and death. Chronic Long term exposure to argon based mixtures has no known health effects. Prolonged exposure to an oxygen deficient atmosphere (below 19% oxygen in air) may affect the heart and nervous system. First Aid Inhalation: In high concentrations may cause asphyxiation. Symptoms may include loss of mobility/consciousness. Remove victim to uncontaminated area whilst wearing self contained breathing apparatus. Victim may not be aware of asphyxiation. Keep victim warm and rested. Call a doctor. Apply artificial respiration if breathing stopped. Advice to Doctor Advise doctor that victim has been exposed to an oxygen deficient atmosphere. General: Rescuers should not enter an oxygen deficient atmosphere without using self-contained full face positive pressure breathing equipment. Rescue personnel should be aware of extreme fire hazard associated with hydrogen rich atmospheres.

6. Fire Fighting Measures Flammability: Highly flammable. Spontaneously flammable in air. Avoid all ignition sources. Fire/Explosion Hazard: Hydrogen is highly flammable and burns with almost invisible flame. Exposure to fire my cause container to rupture/explode. Cylinders involved in a fire/explosion may rocket. Move cylinders from vicinity of fire if safe to do so. Cool cylinders by spraying flooding quantities of

water from a protected location. If unable to keep cylinders cool, evacuate area, minimum distance 200 meters. Do not extinguish a leaking gas flame unless absolutely necessary. Spontaneous/explosive re-ignition may occur. Extinguish any other fire. Extinguishing Media: Water fog or fine water spray. Cool cylinders with water if possible. Hazchem Code: 2SE Recommended Protective Clothing: In confined space use self-contained breathing apparatus.

7. Accidental Release Measure Personal Protection: Personnel engaged in the movement of cylinders shall be provided with safety footwear, safety glasses and leather or PVC gloves. Full cover overalls are recommended. In areas where equipment failure may cause an immediate high concentration of hydrogen, ensure adequate ventilation and have approved self-contained, full face respiratory equipment readily available for emergencies. Spills and Disposal: Ventilate area. Stop leak if it can be done without risk. Allow gas to dissipate to atmosphere. Prevent from entering sewers, basements and workpits, or any place where its accumulation can be dangerous. Reference Guide: Standard SNZ HB 76:2008 Dangerous Goods Initial Emergency Response Guide. AS/NZS 1337 Eye Protection for Industrial Applications AS/NZS 2161.1 Occupational Protective Gloves Selection, use and maintenance AS/NZS 1715 Selection, Use and Maintenance of Respiratory Protective Devices AS/NZS 1716 Respiratory Protective Devices General: Only experienced and properly instructed personnel should handle compressed gases. Open valve slowly to avoid pressure shock. Cylinder contents and identification labels provided by the supplier must not be removed or defaced. Colour coding should not be the only criterion used for content identification.

8. Handling and Storage Handling Flammability: Highly flammable. Spontaneously flammable in air. Avoid all ignition sources.

General: Only experienced and properly instructed personnel should handle compressed gases. Open valve slowly to avoid pressure shock. Cylinder contents and identification labels provided by the supplier must not be removed or defaced. Colour coding should not be the only criterion used for content identification. Approved Handlers: Approved handlers are required if more than 100 m3 is stored on site. Storage: Storage of compressed gas cylinders shall be in compliance with New Zealand HSNO Regulations. Cylinders will be kept away from ignition sources (including static discharges). Cylinders shall be stored in a cool, dry, well ventilated area out of direct sunlight and away from heat and ignition sources. No part of cylinders shall be exposed to temperatures above 50 C. Cylinders shall be stored upright on a level, fireproof floor, secured in position and protected from damage. Full cylinders shall be stored separately from empties. Cylinders should be moved by hand-truck or cart designed for that purpose. Spills and Disposal: Ventilate area. Stop leak if it can be done without risk. Allow gas to dissipate to atmosphere. Prevent from entering sewers, basements and workpits, or any place where its accumulation can be dangerous. 9. Exposure Controls, Personal Protection Exposure Standards: Simple asphyxiant. Engineering Controls: Provide adequate local exhaust and dilution (general) ventilation and supply sufficient replacement air to maintain oxygen concentration above 19%. Personal Protection: Personnel engaged in the movement of cylinders shall be provided with safety footwear, safety glasses and leather or PVC gloves. Full cover overalls are recommended. In areas where equipment failure may cause an immediate high concentration of hydrogen, ensure adequate ventilation and have approved self-contained, full face respiratory equipment readily available for emergencies. Reference Guide: AS/NZS 1337 Eye Protection for Industrial Applications AS/NZS 2161.1 Occupational Protective Gloves Selection, use and maintenance AS/NZS 1715 Selection, Use and Maintenance of Respiratory Protective Devices AS/NZS 1716 Respiratory Protective Devices

10. Stability and Reactivity Flammability: Highly flammable. Spontaneously flammable in air. Avoid all ignition sources. Materials Compatibility: Hydrogen is non-corrosive and can be used with all commonly used, non-reactive metals at room temperature and low pressure. At higher pressures, hydrogen causes embrittlement of some materials, particularly cold worked ferritic steels. Most elastomers are compatible with hydrogen.

11. Toxicological Information. No known toxicological effects from this product.

12. Disposal Considerations Do not discharge into areas where there is a risk of forming an explosive mixture with air. Waste gas should be flared through a suitable burner with flash back arrestor. Do not discharge into any place where its accumulation could be dangerous.

Methane 1. Product Name CHEMICAL NAME; CLASS

: Methane - CH4, Gaseous Methane - CH4, Liquefied (Cryogenic)

PRODUCT USE: Fuel and for general analytic/synthetic chemical uses.

2. Physical and Chemical Properties Molecular weight Molecular formula Boiling/condensation point Melting/freezing point Critical temperature Critical temperature 16.05 g/mole C-H4 -161.6 C (-258.9 F) -182.6 C (-296.7 F) -82.4 C (-116.3 F) 0.55 (Air = 1) Liquid Density@BP: 26.5 lb/ft3 (424.5 kg/m3) 23.6128 0.04235

Specific Volume (ft 3/lb) Gas Density (lb/ft 3)

3. Composition, Information on Ingredients CHEMICAL NAME CAS # Mole % EXPOSURE LIMITS IN AIR ACGIH-TLV OSHA-PEL NIOSH OTHER IDLH TLVp STEL PEL STEL ppm ppm pm ppm ppm ppm There are no specific exposure limits for Methane. Methane is a simple asphyxiant (SA). Oxygen levels should be maintained above 19.5%. None of the trace impurities in this product contribute significantly to the hazards associated with the product. All hazard information pertinent to this product has been provided in this Material Safety Data Sheet, per the requirements of the OSHA Hazard Communication Standard (29 CFR 1910.1200) and State equivalent standards.

Methane

74-82-8 > 99%

< 1% Maximum Impurities

4. Hazard Identification Symptoms of over exposure by route of exposure: The most significant route of overexposure for this gas is by inhalation. The following paragraphs describe symptoms of exposure by route of exposure. Inhalation : High concentrations of this gas can cause an oxygen deficient environment. Individuals breathing such an atmosphere may experience symptoms which include headaches, ringing in ears, dizziness, drowsiness, unconsciousness, nausea, vomiting, and depression of all the senses. Under some circumstances of overexposure, death may occur. The effects associated with various levels of oxygen are as follows:

Concentration 12-16% Oxygen 10-14% Oxygen 6-10% Oxygen Below 6%

Symptoms of Exposure Breathing and pulse rate increased, muscular coordination slightly disturbed. Emotional upset, abnormal fatigue, disturbed respiration. Nausea and vomiting, collapse or loss of consciousness. Convulsive movements, possible respiratory collapse, and death.

Other potential health effects Contact with cryogenic liquid or rapidly expanding gases (which are released under high pressure) may cause frostbite. Symptoms of frostbite include change in skin color to white or grayish-yellow. The pain after contact with the liquid can quickly subside.

Health effect or risks from exposure: (An Explanation in Lay Terms). Overexposure to Methane may cause the following health effects: 1 Acute : The most significant hazard associated with this gas is inhalation of oxygen-deficient atmospheres. Symptoms of oxygen deficiency include respiratory difficulty, headache, dizziness, and nausea. At high concentrations, unconsciousness or death may occur. Contact with cryogenic liquid or rapidly expanding gases may cause frostbite. Chronic: There are currently no known adverse health effects associated with chronic exposure to Methane.

5. First Aid Measures Remove victim(s) to fresh air as quickly as possible. Trained personnel should administer supplemental oxygen and/or cardio-pulmonary resuscitation, if necessary. Only trained personnel should administer supplemental oxygen. In case of frostbite, place the frostbitten part in warm water. DO NOT USE HOT WATER. If warm water is not available, or is impractical to use, wrap the affected parts gently in blankets. Alternatively, if the fingers or hands are frostbitten, place the affected area in the armpit, Encourage victim to gently exercise the affected part while being warmed. Seek immediate medical attention. Victim(s) must be taken for medical attention. Rescuers should be taken for medical attention, if necessary. Take copy of label and MSDS to physician or other health professional with victim(s).

6. Fire Fighting Measures Extinguishing Media : Dry chemical, carbon dioxide, or water.

Special Fire Fighting Instructions: Evacuate all personnel from area. If possible, without risk, shut off source of methane, then fight fire according to types of materials burning. Extinguish fire only if gas flow can be stopped. This will avoid possible accumulation and re-ignition of a flammable gas mixture. Keep adjacent cylinders cool by spraying with large amounts of water until the fire burns itself out. Self-contained breathing apparatus (SCBA) may be required. Unusual Fire and Explosion Hazards: Most cylinders are designed to vent contents when exposed to elevated temperatures. Pressure in a cylinder can build up due to heat and it may rupture if pressure relief devices should fail to function. Hazardous Combustion Products : Carbon monoxide

7. Accidental Release Measure Steps to be taken is material is released or spilled : Evacuate immediate area. Eliminate any possible sources of ignition, and provide maximum explosion-proof ventilation. Use a flammable gas meter (explosimeter) calibrated for Methane to monitor concentration. Never enter an area where Methane concentration is greater than 1.0% (which is 20% of the lower flammable limit). An immediate fire and explosion hazard exists when atmospheric Methane concentration exceeds 5.0%. Use appropriate protective equipment (SCBA and fire resistant suit). Shut off source of leak if possible. Isolate any leaking cylinder. If leak is from container, pressure relief device or its valve, contact your supplier. If the leak is in the users system, close the cylinder valve, safely vent the pressure, and purge with an inert gas before attempting repairs.

8. Handling and Storage Storage: Store cylinders in a well-ventilated, secure area, protected from the weather. Cylinders should be stored upright with valve outlet seals and valve protection caps in place. There should be no sources of ignition. All electrical equipment should be explosion-proof in the storage areas. Storage areas must meet National Electrical Codes for class 1 hazardous areas. Flammable storage areas must be separated from oxygen and other oxidizers by a minimum distance of 20 ft. or by a barrier of non-combustible material at least 5 ft. high having a fire resistance rating of at least _ hour. Post No Smoking or Open Flames signs in the storage or use areas. Do not allow storage temperature to exceed 125 F (52 C). Storage should be away from heavily traveled areas and emergency exits. Full and empty cylinders should be segregated. Use a first-in first-out inventory system to prevent full containers from being stored for long periods of time. Handling: Do not drag, roll, slide or drop cylinder. Use a suitable hand truck designed for cylinder movement. Never attempt to lift a cylinder by its cap. Secure cylinders at all times while in use. Use a pressure reducing regulator to safely discharge gas from cylinder. Use a check valve to prevent reverse flow into cylinder. Never apply flame or localized heat directly to any part of the cylinder. Do not allow any part of the cylinder to exceed 125 F (52 C). Use piping and equipment adequately designed to withstand pressures to be encountered. Once cylinder has been connected to properly purged and inerted process, open cylinder valve slowly and carefully. If user experiences any difficulty operating cylinder valve, discontinue use and contact supplier. Never insert an object (e.g., wrench, screwdriver, etc.) into valve cap openings. Doing so may damage valve causing a leak to occur. Use an adjustable strap-wrench to remove over-tight or rusted caps. All piped systems and associated equipment must be grounded. Electrical equipment should be non-sparking or explosion-proof. Special Precautions: Always store and handle compressed gas cylinders in accordance with Compressed Gas Association. Local regulations may require specific equipment for storage or use.

9. Exposure Controls, Personal Protection i. Ventilation and engineering Controls:

Use with adequate ventilation. Local exhaust ventilation is preferred, because it prevents Methane dispersion into the work place by eliminating it at its source. If appropriate, install automatic monitoring equipment to detect the presence of potentially explosive air-gas mixtures and the level of oxygen. Monitoring devices should be installed near the ceiling. ii. Respiratory Protection :

Maintain oxygen levels above 19.5% in the workplace. Use supplied air respiratory protection if oxygen levels are below 19.5% or during emergency response to a release of Methane. If respiratory protection is required, follow the requirements of the Federal OSHA Respiratory Protection Standard (29 CFR 1910.134) or equivalent State standards. iii. Eye Protection:

Splash goggles or safety glasses, for protection from rapidly expanding gases and splashes of liquid Methane. iv. Hand Protection:

Wear gloves resistant to tears when handling cylinders of Methane. Use low-temperature protective gloves when working with containers of liquid Methane. v. Body Protection :

Use body protection appropriate for task. Transfer of large quantities under pressure may require protective equipment appropriate to protect employees from splashes of liquefied product, as well as fire retardant items.

10. Stability and Reactivity Stability : Stable. : When ignited in the presence of oxygen, this gas will burn to produce carbon monoxide, carbon dioxide.

Decomposition Products

Materials with which Substance is Incompatible: Strong oxidizers (e.g., chlorine, bromine pentafluoride, oxygen, oxygen difluoride, and nitrogen trifluoride). Hazardous polymerization : Will not occur. Condition to Avoid : Contact with incompatible materials and exposure to heat, sparks, and other sources of ignition. Cylinders exposed to high temperatures or direct flame can rupture or burst.

11. Toxicological Information Toxicity Data Other toxic effects on humans : No specific information is available in our database regarding the other toxic effects of this material to humans. Specific effects Carcinogenic effects : No known significant effects or critical hazards. Mutagenic effects : No known significant effects or critical hazards. Reproduction toxicity : No known significant effects or critical hazards.

12. Disposal Considerations Preparing Waste for Disposal : Product removed from the cylinder must be disposed of in accordance with appropriate Federal, State, and local regulations. Return cylinders with residual product to Airgas. Do not dispose locally

Bio-oil 1. Product Name Common name Other names Packaging sizes Uses : Bio-oil : Pyrolysis oil, bio-crude-oil, bio-fuel-oil. : 25 kg drums, 200 kg drums and 1 tone containers. : Fuel for diesel engine and boiler, transportation fuels, chemicals (renewable energy)

2. Physical and Chemical Properties The physical and chemical properties of the product may vary according to the used raw material, the manufacturing technology and the delivered batch. The data below is representative of a typical. Colour Odour Density Water content Water insoluble Log Pow Viscosity-kinematics Surface tension pH Flash point Initial boiling point Explosive properties Vapour pressure Pour point Auto ignition temperature Miscible with Not miscible with Dark brown viscous liquid Strong characteristic, smoky Close to 1.2 kg/l 25 % 20 % (pyrolytic lignin) No data available cSt 225 at 20 C; 30 at 50 C mN/m 29.2 2.5 Data is unreliable ranging from 40 C to over 110 C < 100 C (beginning of the distillation) Not heat or shock explosive Approximately 5 kPa at 38 C -20 C About 500 C Acetone, methanol, ethanol Hydrocarbons; water above 50% weight concentration

3. Composition, Information on Ingredients Technological processes used in production of the substance: Fast pyrolysis / Fluidized bed reactor / Circulating fluidized bed / Ablative Pyrolysis reactor / Vacuum pyrolysis. List of some chemicals that have been identified in the literature in biomass derived pyrolysis liquids. The yield given is the largest reported yield on a wet liquid basis. Only those chemicals that have been repeatedly reported are included. Acids : Formic acid < 10% / Acetic acid 10% Esters : Methyl formate < 1.9%

Alcohols : Methanol < 1.4% / Ethanol < 3.6% / Ethylene glycol < 1.1% Aldehydes : Formaldehyde < 2.4% / Acetaldehyde < 8.5% / Glyoxal / Acroleine / Methylglyoxal < 4% Ketones : Acetone < 2% / 2-Butanone Phenols : Phenol < 2.1% / Methyl phenols / 2-Ethylphenol / Hydroquinone / Catechol < 5% Guaiacols : 2-Methoxyphenol / 4-Methylguaiacol Syringols : 2,6-Dimethoxyphenol Sugars : Fructose / 1,6-anhydroglucofuranose Furans : Fururyl alcohol < 5.2% / 2-Furanone Misc. Oxygenates: Hydroxyacetaldehyde < 15.4% / Hydroxyacetone / Acetal Alkenes : Dimethylcyclopentene Nitrogen compounds: none 4. Hazard Identification Fire and explosion hazard: Flammable liquid at extremely high temperatures. Slow evaporation rate. Not an explosive when subjected to heat or shock. Health hazard: Primary routes of exposure: skin contact, eye contact, ingestion. Eyes: Corrosive, causes burns, severe corneal injury. Skin: Corrosive, causes burns or strong irritation. Ingestion: Causes burns to mouth, oesophagus and gastrointestinal tract if swallowed. Inhalation: Causes irritation to the respiratory tract. 5. First Aid Measures Eyes:

Immediately flush eyes with plenty of tepid water for at least 15 minutes, occasionally lifting the upper and lower lids. Any contact lens must be removed. Get medical attention even if the injury appears to be mild. Skin contact: Remove all contaminated clothing immediately and wash affected skin area with soap and water. Ingestion: First immediately rinse your mouth several times with water. Should the product be swallowed administer 2-3 glasses of water for dilution. Do not induce vomiting. Stay calm and seek medical advice. Inhalation: If eye, nose or throat irritation from dust or mists develops, move to fresh air until symptoms disappear. Generalities: Give nothing by mouth to an unconscious person. If breathing is irregular or has stopped, give artificial respiration.

In all cases of doubt or if symptoms persists, seek medical attention and show this sheet to the doctor. Antidote: No specific antidote exists. The product is acidic (pH 2 -3) and is partly soluble in water. Treat symptomatically 6. Fire Fighting Measures Extinguishing media: Water, carbon dioxide, foam, dry powder. Use water spray to cool product containers and tanks near the fire. Special exposure hazards in a fire: Do not inhale smoke from the fire. Wear self-contained breathing apparatus and full protective clothing. Explosion risk due to pressure increase into containers placed near a fire. The heat may melt the containers allowing the content to mix with extinguishing water. 7. Accidental Release Measure Personal precautions : evacuate people upwind from the spill area. Environmental precautions : do not allow the product to enter drains or surface water. Methods for cleaning up: To handle spills, the following preliminary advices are given. Small quantities (< 1000 ml) The suggested actions for such spillage are: Wear rubber gloves and suitable eye and face protection. If there is an inadequate ventilation, a suitable organic vapours filter mask or NIOSH approved respirator must be worn. Cover contaminated area with an inert adsorbent e.g. vermiculite, sawdust. Take up the used adsorbent and place it in a container for disposal or incineration. Large quantities (> 1000 ml) For spillage of significant quantities first evacuate rapidly workers present in the area and then take the same actions as described above.

8. Handling and Storage Handling Combustible. Keep away from sources of ignition. Take precautionary measures (e.g. earthing) against electrostatic discharges. While transferring the product and opening containers, avoid inhalation of vapours or gases. Ensure good ventilation when handling the product. During tank cleaning operations follow special instructions provided by the manufacturer. Storage The product must be stored in containers suitable for combustible liquids and resistant to acids. Keep containers tightly closed at temperatures below 25 C in a ventilated area. The product contains compounds that may either consume oxygen creating an under-pressure in the container; or may emit vapours that create an overpressure in the container. Recommended storage materials: acid-proof steel, plastics (PETE, PP, HDPE). Filled containers may be gently heated to not more than 50 C before use for transfer of contents. 9. Exposure Controls, Personal Protection Engineering controls Provide local and general exhaust ventilation to effectively remove and prevent vapors and mists generated from the handling of this product. Ensure that eyewash station and safety showers are proximal to the workplace location. Personal protective equipment: Eyes/Face Wear safety glasses, chemical goggles if splashing is possible, or to prevent eye irritation from heated vapours or mists. Skin/Hands/Feet Wear chemically resistant gloves (nitrile gloves or thermally insulated gloves when handling hot products) and footwear with good traction to avoid slipping. If splashing or contact with hot material is possible, consider the need for use of an impervious overcoat. Remove contaminated clothing and clean before reuse. Fire resistant or natural fibre clothing is recommended. Respiratory If ventilation is not sufficient to effectively prevent aerosols or vapours, or if airborne concentrations are above the applicable exposure limits, use a NIOSH approved organic vapour cartridge respirator. Air supplied breathing apparatus must be used when airborne concentration may exceed the limits of the air purifying respirator used.

General Personal protective equipment (PPE) should not be considered a long-term solution to exposure control. Consult a competent industrial hygiene resource, the PPE manufacturers recommendation, and/or applicable regulations to determine hazard potential and ensure adequate protection. Threshold Limit Values (MAK-values) of some chemicals: Chemical name Acetaldehyde Acetone Formic acid Acetic acid Methanol Formaldehyde Furfuryl alcohol 10. Stability and Reactivity Chemical stability : stable under normal conditions of use and storage. Chemical stability : conditions to avoid Heating above 100 C : polymerization may occur with release of harmful or toxic fumes (carbon monoxide carbon dioxide, formic acid, formaldehyde, methanol, acetaldehyde, acroleine and other organic compounds). Corrosivity : reacts with mild steel and impure copper due to high acidity. 11. Toxicological Information. This sample has been obtained under operating condition of temperature of 500 C. LD50 (oral, rat): >2000 mg/kg/body weight 7-days oral, gavage, rats: At 150 mg/kg/body weight, there were no clinical signs of toxicity, a slight reduction in the body weight gain of the females and no effect on food consumption. No macroscopic abnormalities were observed. Acute dermal toxicity: Test not performed as the product is corrosive. Dermal Irritation (rabbit): Corrosive Eye Irritation (not done for ethical reason): Corrosive Inhalation: Avoid inhalation as the product may contain hazardous substances depending on the manufacture process and temperature. Skin sensitization (LLNA, mice): Moderate sensitizer Mutagenic tests: a. Ames test (Salmonella typhimurium): Positive, the product is mutagenic in this test. b. Bone marrow micronucleus test by oral route gavage in mice: Negative c. Micronucleus test in L5178 TK mouse lymphoma cells: Light mutagenic activity Teratogenicity: No known or listed teratogenic effects. CAS# 75-07-0 67-64-1 64-18-6 64-19-7 67-56-1 50-00-0 98-00-0 MAK-values in ppm or ml/m3 50 500 5 10 200 0.3 10

Reproductive effects: No information available. Neurotoxicity: No information available. The product contains traces of substances classified as carcinogenic (e.g. formaldehyde, acetaldehyde, and furfural).

12. Disposal Considerations Product waste is classified as hazardous waste. Do not allow this product to reach drains or ground water. Follow national and municipal regulations obtained from local authorities.

16.Appendix 5

Figure 1: Treated water standard

Figure 2: Air pollutant emission standard [21]

Table 1: Main environmental pollution and pollution control method Type of pollution Dust Source Control method

Generated from receiving & grinding of EFB

EFB is stored in closed compound to reduce dust traveling and protect the EFB from unwanted pollutants Furnace is installed with a filter to control the emission of gas to the atmosphere The ash will be spray with some ash water to keep dust free and the ash is transported by open truck to designated area. The collected ash can sell to cement manufactured or used as fertilizer.

Ash

Generated from furnace due to burning of charcoal

Carbon dioxide

Generated from high pressure thermal treatment of bio oil to reduce the oxygen content in oil. Generated due to high pressure thermal treatment of bio oil

Aqueous effluents

Carbon monoxide

Generated from pyrolysis process of EFB

Organic waste water

Generated from the hydrodeoxygenation process of bio oil

The carbon dioxide is collected using scrubber to react with hydrogen to form methane gas via methanation. The methane gas act as by product and sell to market. The aqueous effluent consists of mixture of organic matter such as acetic acid, ethylene glycol and acetone. The organic matter is hydrolysis to form hydrogen gas and carbon dioxide. The carbon dioxide and hydrogen gas is reacted in methanation process. Carbon monoxide is found in the non-condensable gas from the vapor. The carbon monoxide which has the flammable properties is burned in furnace to reduce the toxic emission. The water is treated via anaerobic digestion which will produce methane gas to produce energy for the plant.