October 2013, Volume 4, No.

5
International Journal of Chemical and Environmental Engineering

Thermo-Economic Analysis of a Novel Conceptual

Process Model for Sustainable Power Plants using
Empty Fruit Bunches
Dhanaraj Turunawarasua,* ; Yen Pinng Chana ; Wan Petra Anisha Wan Muhaiminb ; Lian Hung Honb ; Osama
Bukhari Syedb ; Thi Hoai Vy Nguyenb ; Azry B Borhanb
a

Department of EngineeringPETRONAS , Kuala Lumpur

Department of Chemical Engineering,Universiti Teknologi PETRONAS (UTP)
*
Corresponding Author E-mail:
dhanarajturunawarasu@gmail.com
b

Abstract:

Empty Fruit Bunch waste generation rate from the oil palm industry in Malaysia reaches up to 280,000 tons per year. Large amount of
oil palm wastes available spell biomass energy potential. Although the more common methods in managing oil palm wastes are
incineration, anaerobic decomposition and fast pyrolysis, to be able to manage wastes while generating sufficient power and being free
of carbon footprint is a challenge. This paper has its focus set on utilizing empty fruit bunch (EFB) from oil palm because 23% of
palm wastes are made up of EFB. A technology that can convert waste into energy while at the same time able to recover water from
the biomass waste is an entirely new notion. The main concept here is that the high water content in EFB be extracted for steam
generation. Steam generated coupled with flue gas produced from incineration of biomass wastes will then both lead to power
generation, thus creating a sustainable EFB waste management system with production of useful side-products. With a novel
incinerator cum boiler design and utilization of steam turbine, the proposed biomass waste management and power generation system
is actually self-sustainable and capable of power export of up to 10MW with an additional 2.5MW reserved for auxiliary purposes.
Along with economic analysis and simulation using HYSYS, the plant has proven its functional, environmental and economic
feasibility; based on Malaysian data as reference.
Keywords: EFB; waste management; incinerator cum boiler; self-sustainable; environmental; energy

1. Introduction
Incineration technology is not new in Malaysia. However,
to be able to produce sufficient power while being free of
carbon footprint is the bigger issue. Our aim therefore, is
to design a biomass power plant that brings forth a
sustainable and environmental friendly solution to answer
the need of transforming biomass waste effectively into
value added products that preserves the livelihood of
people while achieving and exceeding the baseline of zero
emission [1],[2].
Based on a study done by Mahlia et al. [3] on alternative
energy source from palm wastes industry for Malaysia
and Indonesia, a mill in Malaysia with a capacity of 30
tons fresh fruit bunch (FFB)/hr have shown that fiber and
shell from processing FFB can be used as fuel in energy
production. This proves the plausibility of power
generation from oil palm waste source. Here, the focus is
set on using empty fruit bunch (EFB) because 23% of
palm wastes are made up of EFB [4]. Now, as reported by
the Malaysian Department of Environment, water content
of EFB can be as high up to 63.8wt [3]. This can be
severely unfavorable for incineration because water
content hinders combustion. Since EFB contains high

percentage of water content, it actually gives light to the

possibility of utilizing the extracted water for good.
A technology that can convert waste to energy while at
the same time can also recover water from the biomass
waste, is an entirely new concept to implement. The gist
of this plant design is that the high water content in empty
fruit bunch (EFB) be extracted for steam generation.
Steam generated coupled with flue gas produced from
incineration of biomass wastes shall both lead to power
generation- expected to be able to meet the auxiliary
needs of the plant and in excess for power export; thus
creating a self-sustainable EFB waste management
system with production of useful side-products as well.
Although the more popular methods in managing empty
fruit bunches (EFB) are direct fired combustion,
anaerobic digestion, pyrolysis and torrefaction, the future
of energy generation and environmental preservation calls
for a sustainable technological solution that can dispose
EFB, turn it into biomass energy in order to power life in
an economical and carbon free way [4], [5].
Development of sustainable renewable energy,
contribution to effective waste management and

Thermo-Economic Analysis of a Novel Conceptual Process Model for Sustainable Power Plants using Empty Fruit Bunches

preservation of environment while being economical can

be anticipated from the proposed conceptual plant.
This paper aims to illustrate:
The conceptual design of a zero emission biomass
power plant that is able to supply 10 MW net
electricity to the Peninsula Malaysia National Grid
(PMNG) electricity distribution system
The feasibility studies of the power plant from
material and energy balance, process flow, process
simulation and economic analysis point of view

2. Methodology
2.1 General Process Description
In our practical process, EFB will be processed using the
direct combustion method; the flue gas is then used to
generate steam, converted to electricity via a steam
turbine.
First, empty fruit bunch (EFB) will go through drying
using the heat from the spent flue gas of the incinerator
because removal of moisture improves combustion
efficiency.
The moisture is then collected, condensed and filtered for
use, to significantly reduce the amount of make-up water
required for the boiler. The dried EFB later enters the
incinerator and is combusted. Here, the incinerator is
encased by the boiler, which absorbs combustion heat lost
through the walls of the incinerator. Ash from the
incinerator will subsequently be collected and sold
separately as fertilizer ash for agricultural uses.
At the same time, flue gas will pass through tubes
immersed in the water inside the boiler, thereby
transferring its heat to generate steam. With the spent flue
gas still having a relatively high amount of heat, it is then
used in the aforementioned drying of EFB. The steam
generated shall generate electricity via a steam turbine,
which can then be exported or used on-site. Fig. 1 below
shows the process flow diagram of our proposed empty
fruit bunch management and power generation system.

2.2 Empty Fruit Bunch Drying Process

To improve the combustion efficiency, the water-rich EFB
waste should first be dried. Its water content is actually a
potential water source that can be utilized, of which most
conventional thermal waste management techniques do
not take advantage of. It is proposed that a direct (hot air)
rotary dryer be used, due to its potential in terms of
solvent recovery (see Fig. 2).
Atmospheric air is first heated using spent flue gas, which
still contains a significant amount of waste process heat
that cannot be discharged directly to the atmosphere and
should be recovered with this heat integration. The heated
atmospheric air is then directed in a counter current
fashion against the wet EFB waste, thereby achieving the
desired drying effect. The rotating motion of the dryer
helps maximize the exposed surface area and encourage
even drying. The dried waste is then sent directly to the
incinerator.
Meanwhile, the humid air is passed through a climate
changer or dehumidifier, which is essentially made of
cooling coils. Water runs through them as the refrigerant,
and chilling is achieved using a packaged chillers. The
condensate is then collected and sent for treatment.
Approximately 168000 ton/year of water to be used for
steam generation can be produced from this drying,
condensation and filtration system. Fig. 3 below shows
the cross sectional view of the rotary dyer.

Figure 2. EFB Rotary Dryer

2.3 Boiler Feed Water Treatment

Figure 1. Process Flow Diagram

There are two water sources for the generation of steamone from the recovered condensate from drying process
and the other from battery limits. These sources
(collectively feedwater) are first filtered in a textile prefilter bed to remove solid impurities such as minute ash
carryover from the rotating dryer. The filtered condensate
enters a tank, where biocide is injected to kill
microorganisms that may cause biological fouling to the
pipes. In order to make up for the steam lost in the
downstream process, collected steam condensate is also
added here. Next, a degassing unit is employed to strip off
the various dissolved gases from the rotating dryer. The
stripping medium is exhausted low pressure steam from
steam turbine. Right after the degassing unit is the
activated carbon filter. The degassing unit also serves the

312

Thermo-Economic Analysis of a Novel Conceptual Process Model for Sustainable Power Plants using Empty Fruit Bunches

purpose of removing dissolved carbon dioxide which can

shorten the service duration of the activated carbon filter.
The activated carbon filter removes very fine impurities
and dissolved organics. The condensate further passes
through the demineralization unit, which removes ions
that can cause scaling using resin ion exchange
technology.
Finally, a final polishing unit serves to ensure that the
boiler feed water is up to the desired quality, thereby
minimizing the negative impact to the boiler. The
following Fig. 3 shows the process flow diagram of the
BFW treatment.

Figure 3. BFW Treatment

Since the incineration is partially adiabatic, about 0.36

MW heat is expected to be released through radiation and
convection from the incinerator wall, which will be
reserved for steam generation as well because the
incinerator is designed in such a way that it is contained
in a boiler system. In common technology nowadays, heat
dissipated from the incinerator wall is basically released
into the environment, thus causing global warming.
Here, the boiler is estimated to require 61 MW heat to
evaporate the water in the boiler in order to produce
superheated steam at 500C, 50 bar for power generation
(12.5 MW) via steam turbine.
For the typical range of moisture extracted from the EFB,
energy balances have showed that the cooled flue gas still
has a significant amount of energy at 480C. This is the
reason cooled flue gas is recycled back to the drying unit
to heat the atmospheric air where it will be directed in a
counter current fashion against the wet solid waste,
thereby achieving the desired drying effect in a
sustainable way.
With the novel incinerator cum boiler design that is
coupled with heat integration work, the system is
expected to deliver sustainability and energy efficiency.
Detailed Material and Energy Balance was carried out
prior to process simulation to justify the feasibility of the research.

3. Process Simulation

2.4 Incinerator-Boiler Unit

This unit is the heart of the process. It is a novel
combination of a boiler and an incinerator, designed to
capture the combustion heat lost through the walls of the
incinerator, as shown in the Fig. 4.

Figure 5. ASPEN HYSYS Model of EFB Power Plant

Figure 4. Incinerator-Boiler Unit

The dried EFB and 15% of excess air will first be fed into
the incinerator where combustion will occur at 1800C, 1
atm. The source of ignition for the incinerator shall take
place in a spark plug concept.
The total heat that is carried by the flue gas is
approximately 75 MW, which will be utilized for steam
generation by circulating it back into the boiler through
heat exchanging tubes that are immersed in the water.

Figure 6. ASPEN HYSYS Model of Acid Gas Removal from

Incinerator Hot Flue Gas

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Thermo-Economic Analysis of a Novel Conceptual Process Model for Sustainable Power Plants using Empty Fruit Bunches
Table 1: Stream Specifications on Incinerator cum Boiler Unit

Stream
Temperature (C)
Pressure (kPa)
Molar Flow (kmol/h)
Mass Flow (kg/h)
C
H
O
S
CO2
H2O
SO2
NO
N

Dried EFB

Air For
Combustion

27.04
80
1067
1.18E+04

25
100
3854
1.11E+05

0.2437
0.1874
0.0688
0.0004
0.0000
0.4993
0.0000
0.0000
0.0004

0.0000
0.0000
0.2100
0.0000
0.0000
0.0000
0.0000
0.0000
0.7900

Hot Flue
Gas

Cool Flue
Gas

1456
35.09
80
70
4221
4221
1.22E+05
1.22E+05
Composition
0.0000
0.0000
0.0095
0.0095
0.0008
0.0008
0.0000
0.0000
0.1108
0.1108
0.0852
0.0852
0.0002
0.0002
0.1443
0.1443
0.6493
0.6493

Ash

BFW

HP Steam

1456
80
52.03
6.27E+02

26.03
4980
3582
6.45E+04

495
4970
3582
6.45E+04

0.9985
0.0000
0.0000
0.0015
0.0000
0.0000
0.0000
0.0000
0.0000

0.0000
0.0000
0.0000
0.0000
0.0000
1.0000
0.0000
0.0000
0.0000

0.0000
0.0000
0.0000
0.0000
0.0000
1.0000
0.0000
0.0000
0.0000

Table 2. Stream Specifications on Acid Gas Removal Unit

Stream

11

Temperature (C)
Pressure (kPa)
Molar Flow (kmol/h)
Mass Flow (kg/h)
C
H
O
S
CO2
H2O
SO2
NO
N
DEA

40
78.11
4211
1.22E+05
0.0000
0.0095
0.0008
0.0000
0.1108
0.0852
0.0002
0.1443
0.6492
0.0000

Lean DEA

40
88.34
110
110
3582
3583
2.90E+05
2.90E+05
Composition
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0815
0.1556
0.2191
0.2041
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.6994
0.6403

To SO2/NO
Removal
Unit
62.94
78
3891
1.08E+05

Rich
DEA

CO2

62.6
78
3912
3.05E+05

28.62
110
329.9
1.42E+04

0.0000
0.0103
0.0009
0.0000
0.0038
0.0889
0.0002
0.1565
0.7043
0.0000

0.0000
0.0000
0.0000
0.0000
0.1556
0.2041
0.0000
0.0000
0.0000
0.6403

0.0000
0.0000
0.0000
0.0000
0.9642
0.0357
0.0000
0.0000
0.0000
0.0000

4. Economic Analysis
The total equipment cost, fixed capital investment cost,
total production and operating cost have been calculated
to verify the plants economic feasibility. Profitability
analysis was also performed by calculating the internal
rate of return (IRR), payback period, both discounted and
non-discounted cash flow. Follow summarizes the findings:

Based on the material and energy balances, the power

generation plant is able to export 12.5MW of electricity
power in which 2.5MW will be used for auxiliary
purposes. According to publication from the Malaysian
Ministry of Energy, Green Technology and Water, the FiT

Table 3. Economic Analysis

Assuming that the plant operates for 330 days/year, the

preliminary economic calculations have proven that the
generated power is not only able to feed into the national
grid for good with spare for auxiliary purposes, it is able
to generate a steady return for the investment- striking
two birds with one stone.

Equipment Cost [7]

Fixed Capital Investment
Total CAPEX [8]
Total production cost [9], [10]
Total Annual Revenue
Gross Profit
Unit Profit
Payback period
IRR (%)

2.415 mil US$

11.907 mil US$
15.054 mil US$
8.416 mil US$/ yr
14.404 mil US$
5.988 mil US$
50 US$/tonne
4 year
54

rate for biomass installed capacity of up to 10MW is of

RM0.31/kWh, much to the favour of our plant economics [11].

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Thermo-Economic Analysis of a Novel Conceptual Process Model for Sustainable Power Plants using Empty Fruit Bunches

generation and environmental conservation. In the

future, it is recommended that extent of combustion
reaction be improved while hot utility required for flue
gas pre-heating be reduced through further heat
integration and a better utility system design.

5. Sustainability of System
The proposed power generation plant with oil palm empty
fruit bunch (EFB) as main feedstock here has taken into
consideration some of the key elements of sustainability
issue from the environmental, economic and social point
of views, all as described below [12]:
Water conservation: By fully utilizing the water
content obtained from the drying of EFB and
condensation, the system actually avoids consumption
of any external water supply; for it promotes
sustainable regional water management strategy
through extraction and effective recycling.
Heat conservation: Unlike common systems where
heat loss is a major concern, this system integrates the
heat dissipated from incinerator wall to be a heat
supply to the boiler, added with recycled flue gas energy;
thus supplying reliable energy source while minimizing
unwanted heat release to the environment which in turn
promotes clean energy generation technology.

Waste management: It helps to get rid of the abundant

yet non-sustainable and environmentally worrying
biomass wastes. On the other hand, ash collected from
this process can be further treated to be used as
fertilizer- giving back to the community [13].
Energy efficient: No external power supply is needed
because the utility electricity generated within the
process is expected to operate the dryer, filtration
system, incinerator and turbine. In fact, electricity
generated in this process will mainly be delivered to
the national grid which is not only profitable,
renewable but also sustainable.
Prevention of COx and NOx emission: The
temperature and content of flue gas is kept under

control to prohibit harmful COx and NOx production, which

is currently a global attempt to minimize environmental
pollution and global warming [14], [15].

Acknowledgement

Authors would like to express their gratitude to the

Faculty of Chemical Engineeering,Universiti Teknologi
PETRONAS (UTP), Malaysia for their support.

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6. Conclusion
The proposed system has successfully utilized a nonfossil energy source which is oil palm EFB, where an
appreciable amount of useful energy from the biomass
wastes was fully harnessed.
Detailed mass and energy balance have thereby shown
that the designed plant is capable of delivering 10MW
of electricity to supply the national power grid with an
additional 2.5MW reserved for auxiliary purposes
using 280,000 tons per year of EFB supply.
The plants effluent, gas discharges and operating
hazards were also taken under full consideration to
abide by local environmental and safety regulations.
With that, a thorough economic analysis which leads
to an expected gross profit of 5.988mil US$ per year
and estimated payback period of 1 year further strengthened
the economic plausibility of the designed plant.
This novel approach in harnessing energy and
recovering water in a sustainable biomass
management system should be able to fulfil the local
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