Pilot Scale Biochar Production From Palm Kernel Shell (PKS) in A Fixed Bed Allothermal Reactor
Pilot Scale Biochar Production From Palm Kernel Shell (PKS) in A Fixed Bed Allothermal Reactor
Pilot Scale Biochar Production From Palm Kernel Shell (PKS) in A Fixed Bed Allothermal Reactor
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Pilot Scale Biochar Production From Palm Kernel Shell (Pks) In A Fixed Bed
Allothermal Reactor
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ZAINAL HARYATI*; SOH KHEANG LOH*; SIENG-HUAT KONG** and ROBERT THOMAS BACHMANN‡
ABSTRACT
Oil palm biomass wastes such as oil palm fronds (OPF), empty fruit bunches (EFB) and palm kernel shells
(PKS) are amongst the most abundantly available agricultural residues in Malaysia. Of these, an average
0.16 t PKS per tonne crude palm oil (CPO) is commonly used in palm oil mills as boiler fuel to generate
steam and electricity, while the remaining unused 0.20 t PKS per tonne CPO are often sold as fuel. In order
to diversify and add value to the remaining PKS, it is proposed to convert it into biochar to sequester CO2
and improve the productivity of low-fertility soil. In this study, PKS was carbonised under allothermal
conditions at various temperatures (400°C to 600°C) and residence times (30 and 60 min) using the biochar
experimenters kit (BEK). Biochar yield decreased from 52.1 ± 15.5 wt% at 400°C (30 min) to 33.4 ± 1.4
wt% at 600°C (60 min), while pH, elemental and fixed carbon content increased with temperature and
residence time. The VM/FC (0.25 to 0.60) and O/C (0.12 – 0.23) ratios suggest that PKS biochar is an
effective carbon sink with a half-life in soil > 100 years.
Date received: 28 November 2017; Sent for revision: 30 November 2017; Received in final form: 16 February 2018; Accepted: 5 July 2018.
or ‘fertiliser-derived’ nutrients (Sohi et al., 2009), the BEK enables researchers to report comparable
improve soil pH and permeability of loamy soils yields in contrast to highly customised reactor types
(Martinsen et al., 2014). currently used (Table 1). Apart from that, the BEK is
Over many centuries, charcoal has been relatively easy to operate as it can feed the original
made using various forms of earth kilns for form of granular biomass such as PKS and therefore
metallurgical, cooking, heating and medical potentially save time, energy and cost. The quantity
applications (Kortzfleisch, 2009). However, the produced is also sufficient to conduct nursery and
traditional charcoal production technology releases field trials compared to laboratory-scale pyrolysis
condensable and non-condensable gases into the reactor (Table 1).
environment causing health concern. Modern Table 2 summarises the various process
biochar production technology must meet stringent conditions used for the production of biochar.
emission criteria while producing high-quality, Generally, the generation of solid, liquid and gaseous
stable biochar at an affordable price. Several products from biomass pyrolysis primarily depends
technologies have been proposed over the past on the feedstock used as well as operating conditions
decade such as top-lit updraft gasifiers (Nsamba such as temperature, heating rate, residence time
et al., 2015), Kon-Tiki earth kiln (Cornelissen et and oxidising agent (Shafizadeh, 1982). The biochar
al., 2016), improved retort kiln (Adam, 2009) and yield under a slow pyrolysis condition is higher
the biochar experimenter kit (BEK) (Boateng than in fast pyrolysis which produces mainly bio-
and Mullen, 2013). The BEK is a unit that can be oil. Most studies used laboratory-scale fixed bed
operated in various modes enabling researchers reactors at temperatures ranging from 400°C to
and practitioners to produce and characterise 800°C with a PKS biochar yield of 23 to 39 wt%.
biochar under allothermal, autothermal, batch and Only one study is available in which PKS biochar
continuous operation conditions. Autothermal may was produced at pilot-scale conducted at one
be defined as a process in which heat is generated temperature and holding time (Kong et al., 2013).
from reactions within the reactor to support This study therefore aims to investigate the
endothermic pyrolytic processes while allothermal effect of pyrolysis temperature and residence time
refers to heat that is produced outside the reactor on biochar and bio-oil yields at pilot-scale under
and transferred through a wall into the interior of fixed-bed allothermal conditions using the BEK and
the reactor to drive endothermic reactions (Karellas, as-received PKS. In addition, the physico-chemical
2015; Nsamba, et al., 2015; Rauch, et al., 2014; Stiller properties of biochar were determine and the
and Hochrinner, 2016). The flexible platform of potential for soil application discussed.
TABLE 1. REACTOR TYPE AND PROCESS CONDITIONS USED FOR CARBONISING PALM KERNEL SHELL (PKS)
Reactor type Capacity Particle Temperature Residence Biochar Bio-oil Reference
size (mm) (°C) time yield yield (wt%)
(min) (wt%, dwb)
Fluidised-bed au 0.3-2 kg feed 1-2 479 – 555 30 – 197 21 – 23 50-53 Choi et al.
(2015)
Fixed bed al 20 kg As received 400 60 29 NR Kong et al.
(2013)
Fixed bed al 0.15 kg 1.7-2.0 400 – 800 60 24 – 35 36 - 46 Abnisa et al.
(2011)
Fluidized-bed au 0.94 kg hr-1 0.125-1.400 478 NR 23 52 Kim et al.
(2014)
Fixed bed au 0.1-0.4 10-20 500 60 32 51 Lee et al.
(2013)
Fixed bed al 0.5 As received 400 – 800 55 – 167 31 – 39 NR Titiladunayo
et al. (2012)
Note: au - autothermal; al - allothermal; NR - not reported; dwb - dry weight basis.
MATERIALS AND METHODS the biochar. There are several pyrolysis modes
available, i.e. bypass mode, retort mode and sweep
Sample Preparation gas mode. In this study, the bypass mode (Figure
3a) was used during start up burning propane gas
PKS (Figure 1) was obtained from Sime Darby to heat up the PKS (20 kg) in the reactor. Once the
Palm Oil Mill in Labu, Negeri Sembilan, Malaysia. reactor reached 100°C, the heat was generated by
Prior to biochar production, the collected PKS was burning the syngas released from pyrolysing PKS
air-dried by spreading on a rain-sheltered concrete using retort mode (Figure 3b).
floor for a few days followed by drying in an oven
at 103°C until the moisture content was <10 wt %.
Experimental Procedures
Figure 1. Raw palm kernel shell (PKS) from palm oil mill. Figure 2. The biochar experimenter’s kit (BEK); white arrows for bypass
mode and black arrows for retort mode (outer layer of the reactor).
a) Biochar Experimenter Kit (the B.E.K.) b) Biochar Experimenter Kit (the B.E.K.)
Multiple mode pyrolysis reactor for characterised Multiple mode pyrolysis reactor for characterised
biochar making all power labs. www.bekbiochar.com. biochar making all power labs. www.bekbiochar.com.
gek@allpowerlabs.org gek@allpowerlabs.org
Bio-oil collector
Biochar collector
Biochar collector
Two pyrolysis parameters were monitored, i.e. used. The proximate analysis was carried out by
temperature (400°C to 600°C) and residence time thermal gravimetric analysis (TGA) (Leco TGA 701)
(30 and 60 min). All experiments were performed according to ASTM D5142. Calorific value (CV) of
in triplicate in batch mode and results presented as biochar was determined with a bomb calorimeter
mean values. The biochar produced was collected (Leco AC-600) according to ASTM D5865-07.
from the second hopper (No. 8, Figure 3b), then Ultimate analysis was done using a CHNS analyser
cooled overnight prior to physico-chemical analyses. (Leco 628) according to ASTM D5373, and the oxygen
Bio-oil was collected from the condenser unit at the (O) content calculated by difference (Equation 3;
end of the run using a pre-weight glass beaker. Titiladunayo et al., 2012). The raw PKS was analysed
The biochar yield was calculated using Equation in a similar manner.
(1):
Wbc O(wt%)=100-C(wt%)-H(wt%)-N(wt%)-S(wt%)-Ash(wt%)
Biochar yield (wt%) = x 100 Equation (1) Equation (3)
W0
where W0 is the dry weight of raw PKS (kg), and RESULTS & DISCUSSION
Wbc is the weight of biochar produced (kg).
Biochar and Bio-oil Yield
The bio-oil yield was calculated using Equation
(2): The PKS pyrolysis product distribution (Figure
Wbo 4) was found to range from 33 - 52 wt% (dwb) for
Bio-oil yield (wt%) = x 100 Equation (2) biochar (Figure 5), 1 - 5 wt% (dwb) for bio-oil and
W0 43 - 64 wt% (dwb) for pyrogases. Results generally
show a decrease in biochar yield with temperature
where W0 is the dry weight of raw PKS (kg), and and residence time which agrees with literature
Wbo is the weight of bio-oil (kg) collected from the cited in Table 2. The relatively higher yields of
condenser. biochar at lower temperature (400°C) are attributed
to the thermal breakdown resistance of lignin (Ma
Physico-chemical Characterisation of PKS and et al., 2015). Comparing the PKS biochar yield with
Biochar yields from other biomasses under similar process
conditions it can be seen that PKS biochar yield is
Prior to characterisation, the biochar samples greater (Lee et al., 2013; Titiladunayo et al., 2012).
were ground using a Dickson AFY-300 grinder and According to Lehmann et al. (2006), Thomsen et al.
used as it was for analysis. For pH determination, (2011) and Kong et al. (2014), lignin is an important
Enders et al. (2012) protocol was followed using a factor for biochar production. Several authors
calibrated pH meter (BP3001 Trans Instruments). reported a PKS lignin content ranging from 44 wt%
However, instead of 1 M KCl, deionised water was (Abnisa et al., 2013) to 50 wt% (Loh, 2017) which are
70
60
50
Yield (wt%)
40
30
20
10
0
400 500 600
Temperature (°C)
Figure 4. Palm kernel shell (PKS) pyrolysis product yield distribution at different temperature and residence times.
PILOT SCALE BIOCHAR PRODUCTION FROM PALM KERNEL SHELL (PKS) IN A FIXED BED ALLOTHERMAL REACTOR
TABLE 3. PROXIMATE ANALYSIS OF PALM KERNEL SHELL (PKS) AND PKS BIOCHAR
Properties Unit Raw PKS Biochar
PKS 30 min 60 min
Temperature °C - 400 500 600 400 500 600
Calorific value MJ kg-1 19.5±0.6 26.7±2.8 25.1±5.1 29.9±0.6 29.0±0.3 27.9±0.21 28.3±1.2
Moisture content wt% 4.86±1.29 2.20±0.08 3.00±0.04 4.07±0.18 2.46±0.07 3.26±0.16 3.80±0.08
Volatile matter (VM)* wt% 70.7±2.0 38.6±1.1 34.6±1.7 22.8±2.5 31.6±0.5 25.2±0.8 20.0±5.3
Ash content* wt% 2.17±0.59 6.07±0.88 3.73±0.34 5.12±0.63 6.23±0.62 10.3±5.2 5.28±0.29
Fixed carbon (FC)* wt% 22.2±2.2 53.2±1.8 58.7±1.8 68.0±2.3 59.7±0.9 61.3±4.7 70.9±0.4
VM/FC - 3.18 0.73 0.59 0.34 0.54 0.41 0.28
Note: ± SD - standard deviation; * dwb - dry weight basis.
JOURNAL OF OIL PALM RESEARCH
Kong et al. (2013) who found that the value of PKS form cyclic amides such as 2,5-diketopiperazine
biochar at 400°C was pHH2O 6.9, and Lee et al. (2013) (DKP) (Hansson et al. 2003; Becidan et al., 2007;
reported a pHH2O 6.99 at a temperature of 500°C. Liu et al., 2017) which lock up N at temperatures
Biochars (pHbiochar >> psoil) are known to increase soil below 400°C. However, as pyrolysis temperature
pH which helps to alleviate aluminum root stress increases, N content in pyrolysed PKS decreased
(Manickam et al., 2015). The PKS biochar with the (Table 4) probably due to the decomposition of DKP
highest C content (74.2 wt%) was obtained at 500°C and glycosylamine resulting in the formation and
for 30 min reaction. The H and O contents of PKS release of HCN, HNCO and NH3 (Hansson et al.,
decreased during pyrolysis probably caused by 2003; Becidan et al., 2007; Liu et al., 2017). Although
dehydration and decarboxylation reactions (Li et al., major and trace nutrients in PKS and PKS biochar
2007; Jindo et al., 2014; Yu et al., 2016). In addition, were not analysed in this study, Loh (2017) showed
aromatisation and the formation of light molecular that PKS can be potentially used as animal feed
weight hydrocarbons during pyrolysis could also ingredient and soil amendment (Loh et al., 2013). It
reduce the H content (Kim et al., 2010; Mantilla et can therefore be anticipated that the derived PKS
al., 2014). biochar will also inherit these properties.
The sulphur (S) content in raw and pyrolysed The H/C and O/C molar ratios are important
PKS was below the detection limit, while nitrogen indicators of the presence of polar functional
content was found to range from 0.17 wt% in raw to groups, hydrophilic nature of the surface (Chen
0.77 wt% in pyrolysed PKS. The low concentrations et al., 2008; Kearns et al., 2014) as well as biochar’s
of S and nitrogen (N) content in PKS is a common stability (Spokas, 2010). The H/C ratio of raw PKS
feature of ligno-cellulosic material due to a lack of was found to be 2.02 while ratios of 1.36 to 1.47
proteins in non-reproductive plant components were reported by numerous authors (Kawser and
while animal residues have a typical S and N content Ani, 2000; Asadullah et al., 2013; Asadieraghi and
of 2.3 wt% and 12 wt%, respectively (Vassilev et Wan Daud 2014; Ma et al., 2015). Raw PKS had an
al., 2010). Sulphur content in PKS was reported in O/C ratio of 0.61 which agrees well with literature
literature to vary from below detection limit (BDL) values ranging from 0.513 to 0.818 (Kawser and Ani,
(Kawser and Farid, 2000), 0.04 wt% (Asadullah et 2000; Asadullah et al. 2013; Asadieraghi and Wan
al., 2013), 0.1 wt% (Ma et al., 2015) and 0.38 wt% Daud 2014; Ma et al., 2015). The H/C molar ratio
(Asadieraghi and Wan Daud, 2014). Increased levels of PKS biochar ranged from 0.52 and 0.97, while the
of inorganic S in plants is indicative of cultivation O/C ratio varied between 0.12 and 0.23 (Table 3).
on acid sulphate soils, soil contamination with H/C and O/C ratios of < 0.7 and < 0.4 respectively
sulphur due to acid rain or excessive sulphur indicate a good degree of carbonisation of biochar
fertilisation requiring the plants in all cases to store (Kuhlbusch, 1995; Zheng et al., 2010; Kung et al.,
S compounds such as SO4 and sulphate esters in 2013) and its suitability for biochar-soil interaction
plant fluids and vacuoles (Knudsen et al., 2004). The (Camps-Arbestain et al., 2015; IBI, 2015). The H/C
N content ranged from 0.37 wt% (Kawser and Farid, and O/C ratios decreased as pyrolysis temperature
2000) to 0.76 wt% (Asadieraghi and Wan Daud, increased (Krull et al., 2009; Spokas 2010; Enders et
2014) and was found to be greater in pyrolysed al., 2012). According to Spokas (2010), biochars with
PKS arguably due to pre-concentration effects an O/C ratio of < 0.2 can attain half-life > 1000 years
caused by the volatilisation of hemicellulose and while O/C ratio > 0.6 have an estimated half-life
cellulose while proteins either react with cellulose of < 100 years. Therefore, it shows that O/C ratio
to form glycosylamines (Maillard reaction) or of PKS biochars reported here have an expected
half-life of at least 100 to 1000 years thus playing article and the staff of Energy and Environment
a potentially important role in locking up carbon Unit for their thechnical assistance.
while improving plant growth in low-fertility soils.
The C/N ratio of biochar indirectly relates to
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PILOT SCALE BIOCHAR PRODUCTION FROM PALM KERNEL SHELL (PKS) IN A FIXED BED ALLOTHERMAL REACTOR