Evolving circular economy in a palm oil factory: Integration of pilot-scale hydrothermal carbonization, gasification, and anaerobic digestion for valorization of empty fruit bunch

In the context of evolving a circular economy for the palm-oil industry, this article presents a study of oil-palm empty fruit bunch (EFB) conversion and utilization within a palm-oil mill. Pilot-scale hydrothermal carbonization (HTC), washing and gasification processes, as well as anaerobic digestion of the HTC liquid product were investigated. Results showed that the fuel properties of hydrochars had improved. In terms of air gasification, char and tar products accounted for 22.7-33.8 % and 17.3-28.8 %, respectively while CO2/O-2 gasification resulted in 31.3-36.6 % for char and 8.5-30.8 % for tar. In general, hydrochar (HT-EFB) gave the lower tar content compared to washed hydrochar (HTW-EFB) due to the catalytic effects of alkali and alkaline earth metals. Major tar components from HT-EFB and HTW-EFB were aliphatic and monoaromatic hydrocarbons, respectively. Syngas products from air gasification of hydrochars were 39.9-56.5 %, 11.4-21.4 %, and 9.0-14.4 % for CO, H-2 and CH4, respectively while CO2/O-2 gasification products yielded 45.1-56.6 %, 11.6-24.3 %, and 9.4-14.0 % for CO, H-2 and CH4, respectively. The lower heating value of syngas was in the range of 4.7-6.6 MJ/ Nm(3) and cold gas efficiency was approximately 39.1-55.1 %. The cumulative methane from the liquid products amounted to 213.8 and 154.5 L/kg COD for food/microorganism ratios of 1:2 and 1:3, respectively. The mass and energy balance showed that the whole process is promising for future commercialization.