Breag, G.R.

Joseph, P.G.

Coconut Research Institute Repository

COCONUT SHELL CARBONISATION/ WASTE HEAT RECOVERY TECHNOLOGY IN COCONUT PROCESSING IN SRI LANKA G R B r e a g a n d P G J o s e p h Introduction During the last decade the Overseas Develo­pment and Natural Resources Inst i tute (ODNRI) - the scientif ic arm of the British Government ' s Overseas Development Admini­strat ion (ODA) - has had a substantial in­volvement with the Sri Lankan Coconut Industry. The ODA has funded several technical cooperat ion programmes to improve the desiccated coconut , copra, coconut oil extract ion and coir fibre industries and these were implemented jointly by the Sri Lankan Coconut Development Authority (CDA) and ODNRI. These programmes have been monitored and supervised jointly by both the South East Asian Development Division (SEADD) and ODNRI. The broad objective of the col laborat ive programmes is to introduce new and improved methods of processing technology in the Coconut Industry in Sri Lanka with emphasis being placed on insti tutional build­ing. As par t of this wide programme of work, the introduction of the waste heat recovery unit for the production of good quality coconut shell charcoal and provision of process hea t was given a high priority in view of its technical , economic and en­vironmental benefits . This technology has now been successfully introduced to t h e commercia l a rena in Sri Lanka. Traditional charcoal production The tradi t ional pit method of production has a charcoal yield of 25 to 30% of the dry weight of shells used. The charcoal produced by this method is of variable quality, and is often contamina ted with ext raneous m a t t e r and soil. During the process, over 50% of the gross heat content of the shells is lost and at the same t ime, a large volume of obnoxious smoke is evolved to the a tmosphere . This smoke is not only a nuisance but is also a health hazard. In view of this, t he operat ion of the t r a d i t i o n a l pit is e i ther res t r ic ted o r not pe rmi t t ed at all in several a reas in Sn Lanka to prevent environmental pollution and to minimize hea l th hazards to people. The shell the re fo re is often t ranspor ted several miles from the mills where it is genera ted for conversion to charcoal . Applicat ion of the Waste Heat Recovery Uni t (WHU) The ODNRI batch coconut shell carbonisat ion with was t e hea t recovery unit (WHU) as developed virtually e l emina te s t h e smoke problem associa ted with t h e t radi t ional pit method of charcoal product ion and s imul­taneously enables the hea t generated during t h e process - normally lost to t he surround­ings - t o be used in associated heat exchan­ger sys tems in t h e coconut industry. The WHU essent ia l ly has a chamber in which coconut shells a r e conver ted to charcoal and t h e gas evolved during t h e process is subsequently burnt in a furnace /hea t exchan­ger system t o provide process hea t . The control led carbonisat ion of shells in the WHU the re fo re replaces e i ther imported fuel oil or locally felled wood, and subsequently reduces defores ta t ion and associa ted envir­onmenta l problems. In addition, the WHU both maximises t h e uti l isation of shell feed­stock for charcoal production and gives t h e processor a grea ter degree of self-sufficien­cy. This technology has now been introduced by ODNRI in col laborat ion with t h e CDA and mills t o the coconut industry in Sri Lanka. The scope for the appl icat ion and s t a tus of the technology is discussed below. Scope for the application of the technology In the coconut industry the re a re 66 desicca­ted coconut factor ies and 125 oil mills. In each des icca ted factory the re is a s ter i l i ­ser unit which uses e i ther oil or fire-wood and a number of furnance/heat exchanger-/drying system. The majority of the systems used are wood-fired. Overall , the fuel con­sumption of t h e coconut industry is 90,000 MT of wood, 60,000 MT of coconut shells and 1,000 MT of fuel oil. These quant i t ies will of course vary with the annual produc­tion but they indicate the considerable scope for the applicat ion of the WHU technology for the production of good quality charcoal and simultaneously genera t ing process heat . Status of technology The first WHU was manufactured in the UK and was installed in a DC Mill in Sri Lanka in 1983. Af ter complet ing successful t r ia ls two uni ts were fabricated locally, par t ly funded by the CDA, and installed a t a Coopera t ive DC mill. The CDA granted a soft loan for 10 more units to be installed in DC mills. To da te , 21 WHUs have been locally manufactured; of these 18 have been installed and 15 are in commercia l operat ion in des iccated mills and an oil mill. Financial re turns on the application of the units at both the 1.5 and 3.4 MT scales of operat ion are ext remely a t t r a c t i ve . The technology has been primari ly applied in the provision of process heat for drying cut coconut kernels for desiccated coconut manufacture . Other applicat ions of the technology for process hea t include: (a) s teri l isat ion of coconut kernels; (b) drying parings; (c) drying freshly cut coconut n e a t - thus by-passing copra production for the manufacture of good quality oil; (d) copra production and (e) firing multi-fuelled 22 boilers. A collaborative programme of work between the CDA/ODNRI to investigate all these applications is underway. The production of oil from fresh cut kernels is currently being examined at Marawila •Cooperative by CDA/ODNRI and the economic advantages of this method have been compared with the traditional copra drying and oil manufacturing process. A full study to produce copra from its asso­ciated weight of coconut shell is also under­way and the economic and environmental impact if successfully applied would be reali­sed. It is important to note that Sri Lanka produces approximately 150,000 MT of copra and approximately 40% (and above), of the associated shells are used in the curing process (see section above). The application of the WHU technology for both'oil produc­tion from fresh kernels and copra manufac­ture clearly would maximise utilisation of coconut shell which is a valuable resource. Based on commercial and experimental data the technical and economic prognosis is very favourable for the application of this techno­logy for desiccated coconut, copra and oil production in other coconut growing coun­tries. There are also similar opportunities - as in Sri Lanka - to save foreign exchange through substitution of imported fossil fuels and to earn revenue by exporting shell char­coal and activated carbon. Regional application in other coconut growing countries Having successfully introduced the technology to the commercial arena in Sri Lanka, a Regional Workshop on Coconut Shell .Carboni­sation with Waste Heat Recovery Technology in Coconut Processing sponsored by the ODA, CDA and Asian & „ Pacific Coconut Community was held in Colombo in Septem­ber, 1989. This was the first step of a wider ODA funded programme for the intro­duction of the WHU technology to the Region. ADVISORY SERVICE TO THE ESTATE SECTOR The Coconut Research Institute has been entrusted with the responsibility of providing technical and advisory assistance to the coconut estate sector (50 acres and above) by the Ministry of Coconut Industries Under this scheme the Coconut Research Institute endeavours to provide advice on cultivation aspects. The estate sector was requested by a newspaper advertisement to register with the Coconut Research Institute for the above servica If you have not done so yet. please write to the Oirector. Coconut Research Institute. Lunuwila. giving the following information fa registration. (a) Name of the Estate (b) Location (c) Name and address of the owner (d) Person to be contacted at the estate (e) Extent under coconut. 23 

Coconut shell carbonisation/waste heat recovery technology in coconut processing in Sri Lanka

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Coconut shell carbonisation/waste heat recovery technology in coconut processing in Sri Lanka

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