The Sungei Dingin Palm Oil Mill project (2 MWe plant) is implemented by the Kumpulan Guthrie Berhad (KGB) in Malaysia. The KGB Group is one of the leading conglomerates in South East Asia. Its core business includes plantation (oil palm), property development and manufacturing rubber and rubber-wood products. In March 2001, KGB acquired interest in 25 oil palm operating companies from Holdiko Palm Plantations (now known as Minamas Plantation) with estates covering Sumatra, Kalimantan and Sulawesi, Indonesia. This acquisition has increased the Group’s land bank by two-fold to become a major producer of palm oil in the region. The Group is also developing 20,000 hectares of oil palm plantation in Palembang, South Sumatra. It also operates in the United Kingdom, United States of America and Thailand.

The focus and driving force of the Group’s initiatives and practices are based on the principle of sustainable development, biodiversity and environmental management.

Location

Sungei Dingin Palm Oil Mill is located in Sungei Dingin Estate, Karangan, Kedah, West Malaysia.

Economics

The total investment cost amounts to Euro 2.0 million, excluding civil works and building foundations. The expected payback period is 5 years after commissioning.

Technology

The plant consists of the following components:

• Moving-floor Silo Unloading System;
• Combined Watertube-Firetube Steam boiler generating 2 x 22.5 tons/h at 23 bar (g) and equipped with two Dynamic Watercooled Stepgrates;
• Multicyclone Dust Collectors;
• 2 x 2 MWe back pressure turbo-generators (1 running, 1 standby).

Mr. Ong See Boon, Head of Process & Engineering Division, explains, "Sungei Dingin Palm Oil Mill was constructed based on the Eco Tourism Concept. Hence the design of the mill will need to ensure very good conformity with all environmental requirements, in particular with respect to air emission and liquid discharge. The plant is near the Kulim High Technology Park and the Sungei Sedim recreation area." "Vyncke Boilers were chosen based on their design, automation and efficiency. The Dynamic Watercooled Step Grate System will ensure good combustion of the fuel (fiber and shell) in the furnace. This is due to its ability to pre-heat the fuel prior to actual burning and the ability to turn over the fuel as it is pushed over to the next lower level steps, thus exposing any unburned portion of fuel for complete burning. Vyncke has guaranteed a smoke emission level below 400 mg per NM3 which is in accordance with the requirement of Department Of Environment," Mr. Ong continues. Another improvement is the installation of a fully automated Walking Floor Fuel Storage and Feeding System for the feeding the fuel into the boiler furnace. This will ensure the continuous supply of steam to the Turbo-Alternators for power generation and process heating steam in the mill operation. He says, "KKK Steam Turbine was chosen for its trouble free operation and very economical steam consumption characteristics as experienced over the years. Its proven reliability, efficiency and good back-up service are the other important contributing factors for choosing the Turbine for Sungei Dingin Palm Oil Mill."

Supplier Viewpoint (Vyncke Boiler)

"Vyncke offers clean energy technology, turning industrial wastes into process energy. Vyncke, backed with more than 80 years of experience, offers one-stop solutions for quality waste management and energy solutions specifically in biomass and coal." explains Kok Chee Aun, the Sales Engineer of Vyncke in South East Asia. "The Vyncke plant in Sungei Dingin, Kedah includes a moving floor unloading system specifically designed for the palm oil industry. The design has proven to be a cost effective solution towards balancing the fuel fed to the boiler and the steam consumption, especially during the initializing of sterilizers in the mill," says Kok Chee Aun ."The Dynamic Watercooled Stepgrate System, probably the best combustion technology, provides specific control of primary air for combustion and also greatly reduces the formation of ash clinkers. This effectively translates to a long lifetime of the grate. The combinational boiler in the system provides 99% dry steam and is able to respond to a sudden steam peak and maintain a stable pressure level." "The priceless advice from COGEN 3 experts and their assistance in presenting the viability of cogeneration has shown that cogeneration was a worthier solution for Sungai Dingin Palm Oil Mill. The 2 MWe plant is self-sustaining and also provides extra electrical and steam capacity for their milling process."

Supplier Viewpoint (KKK Turbine)

"The Sungei Dingin Palm Oil Mill being built with eco-tourism in mind, the client was looking for environmentally friendly technologies, efficiency, automation, reliability and availability. The selection of the turbine is based on an efficient turbine which can supply power for process requiring 1600 KW, including domestic demand of over 200 KW." says C L Chong, Managing Director of Jebsen and Jessen Technology (JJT). "The first KKK turbine installed in Kumpulan Guthrie Berhad was in 1971 (first generation of KKK turbines). These turbines are still running in good condition. JJT being the sole distributor for KKK steam turbine is therefore the selected supplier based on the fact that KKK turbines have an isentropic efficiency of 66.5 % and that the back pressure system has a cycle efficiency of over 68%. The part load valves also contribute to the higher efficiency when the turbine runs on part load. Turbine selection for Guthrie is based on KKK proven reliability and efficiency together with JJT service back-up.""COGEN 3’s role in promoting environmentally friendly technology, efficiency and reliability has contributed to the success of this cogeneration project."

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