Rapport de Stage PFE Esaïe en-GB

OPTIMISATION OF THE BIOMASS POWER PLANT :
THE CASE OF THE BOLO OIL MILL
DEDICATION
I dedicate this memoir :
 To the Lord JESUS for all he has done and continues to do in

my life.
 To my father KONAN Claude and my mother KOUAME Alice,
for the guidance, love and support I have received from them to
this day.
 To all my family and friends for their support and advice.
 To my classmates, with whom I have shared sadness and joy
throughout this journey.
 In particular, to my special friend KORIA Emmanuela Gémina
for her love and assistance along the way.
 Also to my best friend DOSSO Leïla Fatim for her advice and
support throughout my career.
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option I
ACKNOWLEDGEMENTS
We were able to produce this report thanks to the help and advice of a number of people, to
whom we would like to express our thanks. Our thanks go first and foremost to :
 Dr Moussa DIABY, Director General of the Institut National Polytechnique Félix

Houphouët Boigny de Yamoussoukro (INP-HB);
 Dr Adama Ouattara, Director of the Ecole Supérieure d'Industrie and educational
supervisor;
 The Management and all the teaching staff of the INP-HB.
We would also like to express our gratitude to SIPEF-CI for their welcome and assistance, in
particular to :
 Mr Dossafé KONATE, Head of the BOLO oil mill and our training supervisor, for his
guidance, his great availability, his advice and understanding and his help in writing
this thesis. We would like to express our deepest gratitude to him;
 Mr Stéphane N'GORAN, Laboratory Manager, for his availability and advice
throughout my placement;
 Mr DIABAGATE, Head of Production, for his help in understanding the oil mill
process;
 To all the workers at the oil mill who made my integration easier;
 To Mrs BADO ALICE, Secretary of the R.E.A.I, who helped me to integrate into the
site.
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option II
FOREWORD
The Institut National Polytechnique Félix Houphouët Boigny (INP-HB) was created by
ministerial decree on 04 September 1996 from the merger of four grandes écoles, namely the
Ecole Nationale Supérieure d'Agronomie (ENSA), the Institut Agricole de Bouaké (IAB), the
Institut National Supérieur de l'Enseignement Technique (INSET) and the Ecole Nationale
Supérieure des Travaux Publics (ENSTP), and is based in Abidjan and Yamoussoukro. It is
under the administrative supervision of the Ministry of Higher Education and Scientific
Research and the financial supervision of the Ministry of the Economy and Finance. Its
current Director General is Dr Moussa DIABY. The Yamoussoukro INP-HB comprises 9
schools and a training centre spread over three sites:
1. The Ecole Supérieure d'Agronomie (ESA) and the Ecole Doctorale Polytechnique
(EDP) in the north;
2. The Ecole Supérieure de Commerce et d'Administration d'Entreprise (ESCAE) and the
Ecole Supérieure d'Industrie (ESI) in the centre;
3. The Ecole Supérieure des Travaux Publics (ESTP), the Ecole Supérieure des Mines et
Géologies (ESMG), the Ecole de Formation Continue et de Perfectionnement des
Cadres (EFCPC), the Ecole Supérieure de Chimie, Pétrole et de l'Energie (ESCPE),
the Centre Régional de Formation Supérieure en Métrologie (CREFSEM) and the
Classes Préparatoires aux Grandes Ecoles (CPGE) to the south.
ESI is a school whose mission is to train engineers and senior technicians to meet the many
challenges facing industry. It is managed by Dr Adama Ouattara. It offers the following
courses
1. Industrial Engineering Science and Technology (STGI) ;

2. Telecommunications and Information Science and Technology (STIC) ;
3. Science and Technology of Process Engineering (STGP).
As part of our training in the STGI engineering cycle, we opted for the Production and Energy
Management (PGE) option, which should lead to a 6-month work placement with a view to
obtaining the STGI design engineering diploma, Production and Energy Management option.
It was in this context that we were invited to SIPEF-CI's BOLO site to carry out our end-of-
study work placement.
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option III
CONTENTS
INTRODUCTION
PART 1: PRESENTATION OF THE FACILITY
I. Company presentation
II. Presentation of the end-of-study project
PART 2: STUDY OF THE EXISTING SITUATION
I. Crude palm oil production process and the principle of biomass

cogeneration
II. General description of the biomass plant and other energy sources
III. Analysis of the fuel used
IV. Analysis of the amount of fuel and steam consumed by the boiler
V. Analysis of the specific consumption of turbo-alternators and breakdown of
electrical energy production and consumption
VI. Boiler energy balance
PART 3: OPTIMISING THE PLANT
I. Optimum boiler operation

II. Optimising combustion quality and fuel storage
III. Optimising biomass energy production compared with other energy sources
IV. Optimum choice of turbines
V. Economic study of the project
CONCLUSION
LIST OF FIGURES
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option IV
Figure 1: History of SIPEF-CI....................................................................................................3

Figure 2: BOLO site....................................................................................................................5
Figure 3: Location of SIPEF-CI BOLO......................................................................................6
Figure 4: BOLO E.A.I. organisation chart..................................................................................7
Figure 5: Principle of biomass cogeneration............................................................................14
Figure 6: Operating diagram of the biomass power plant.........................................................15
Figure 7: Illustration of the boiler.............................................................................................15
Figure 8: Schematic diagram of the BoilerMech boiler at the factory.....................................16
Figure 9: View of the TA..........................................................................................................21
Figure 10: Generator visual......................................................................................................22
Figure 11: Breakdown of energy produced by the power plant................................................29
Figure 12: Influence of humidity on PCI..................................................................................41
Figure 13: View of the dryer.....................................................................................................46
Figure 14: descriptive diagram of the dryer..............................................................................46
Figure 15: Rankine cycle..........................................................................................................51
Figure 16: RESPO certificate...................................................................................................XI
Figure 17: Sterilisation cycle...................................................................................................XII
Figure 18: Technical characteristics of the BM boiler...........................................................XIII
Figure 19: Technical characteristics of the TA 1 turbine......................................................XIV
Figure 20: Technical characteristics of the TA 1 alternator..................................................XIV
Figure 21: Technical characteristics of the TA 2 turbine........................................................XV
Figure 22: Generator characteristics......................................................................................XVI
Figure 23: Composition of fresh diets..................................................................................XVII
LIST OF TABLES
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option V
Table 1: Characteristics and roles of conveyors.......................................................................16

Table 2: Characteristics and roles of the draw..........................................................................17
Table 3: Characteristics and roles of locks...............................................................................17
Table 4: Characteristics and roles of air supply units...............................................................17
Table 5: Characteristics and roles of water suppliers...............................................................18
Table 6: Roles of other boiler components...............................................................................19
Table 7: Fuel composition by mass..........................................................................................23
Table 8: Fuel moisture content.................................................................................................23
Table 9: ICP values for each fuel and weighted ICP for each month.......................................25
Table 10: Quantity of fuel consumed by the boiler..................................................................27
Table 11: Specific consumption of turbo-alternators................................................................28
Table 12: Electrical energy produced by the power station and consumed by the plant..........29
Table 13: Bleed rate..................................................................................................................31
Table 14: Suggested ideas for optimum boiler operation.........................................................40
Table 15: Investment cost of the dryer.....................................................................................53
Table 16: Gains made with the installation of the dryer...........................................................53
Table 17: Technical characteristics of the dryer.................................................................XVIII
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option VI
ACRONYMS AND ABBREVIATIONS
SYMBOLS DESIGNATIONS
°C Degrees Celsius
BM BoilerMech
CIE Ivorian Electricity Company
INPHB Centre des Métiers de l'Electricité
SIPEF-CI Société Internationale de Plantations et de Finances - Ivory Coast
E.A.I Agro-Industrial Complex
PCI Lower Calorific Value
PCS Gross Calorific Value
TA Turbo generator
Kg Kilograms
kJ Kilojoules
Kva Kilovolts Ampere
kW Kilowatts
Min Minutes
P Power
w Humidity level
t Tons
l Litre
m3 Cubic metre
FCFA CFA Franc
ηa Apparent boiler efficiency
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option VII
SUMMARY
To solve the problem of fuel shortages while reducing the cost of electricity from other energy
sources, such as the CIE and the generator, due to the rise in the price of diesel and kWh in
Côte d'Ivoire, we were asked to address the following topic: "OPTIMIZATION OF THE
BIOMASS POWER PLANT: CASE OF THE BOLO OIL MILL".
The aim of this project is to optimise the biomass power plant at the oil mill in order to
increase the stock of fuel after the campaign and reduce the plant's electricity consumption
from the CIE and the generator set, by defining optimum operating conditions and making
recommendations to this end. To achieve this, a preliminary study of the existing plant, the
production process and the principle of biomass cogeneration, current performance and the
malfunctions identified enabled us to propose solutions such as the installation of a dryer to
reduce the moisture content of the fuel. The installation of this system will enable us to have a
larger stock of fuel after the campaign and reduce the plant's electricity consumption from the
CIE and the generator set.
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option VIII
INTRODUCTION
The oilseed industry requires an enormous amount of energy to extract and process the juice
from palm trees into oil. This energy is in the form of electricity (for electric motors) or steam
(used in turboalternators, turbo mills and other accessories for the preparation of palm juice).
The insistent demand for steam and electricity has led to excessive fuel consumption,
especially during periods of high production. This gave rise to the following problem: "How
best to use the surplus fuel from periods of high production to power the boiler during periods
of low production, in order to reduce expenditure on electricity from other energy sources".
SIPEF-CI BOLO, in its desire to improve the biomass energy index, submitted the following
topic to us: "OPTIMIZATION OF THE BIOMASS POWER PLANT: CASE OF THE
BOLO OIL MILL".
To carry out our assignment, we have divided the work into three (3) stages. The first stage
will consist of a presentation of the company and the subject. Secondly, we will carry out a
study of the existing situation at the oil mill. The third stage will be devoted in depth to
optimising the biomass plant.
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option 1
PART 1: PRESENTATION OF THE COMPANY AND

THE THEME
I. Company presentation
1. Background to the creation of SIPEF-CI

Côte d'Ivoire's economic policy has long been based on the cultivation of coffee and cocoa.
To diversify its agricultural resources and avert any crisis linked to the global fall in coffee
and cocoa prices, the government decided to increase exports of raw materials, semi-finished
and finished products. To this end, the government launched an oil palm and coconut
plantation programme in 1963. To implement this programme, it created large agro-industrial
companies (SODEPALM, PALMIVOIRE and PALMINDUSTRIE) financed by the State and
the private sector. In 1977, after buying out the private sector's shares in PALMIVOIRE and
PALMINDUSTRIE, the State decided to dissolve PALMIVOIRE and transfer its assets to
SODEPALM.
From the 1990s onwards, the growing economic situation prompted the government to
implement the Structural Adjustment Programme (SAP) steered by the Bretton Woods
institutions. The aim of this programme is to reduce the level of indebtedness in developing
countries by eliminating state management of national public companies. On 15 January
1997, PALMINDUSTRIE was privatised and split into three (3) separate companies: SIPEF-
CI, PALMAFRIQUE and PALMCI.
2. History of SIPEF-CI
Figure 1History of SIPEF-CI
SIPEF-CI has a total surface area of 16,300 hectares spread over three agro-industrial sites
located in the Bas-Sassandra - Bolo, Soubré - Ottawa and Soubré - Okrouyo regions. It had
two oil mills located at the Bolo and Ottawa agro-industrial sites, each with an output of 25
tonnes per hour, which at the time produced an average annual output of 45,000 tonnes of
crude palm oil. Following the merger of United Oil Company (UOC) in 2004, SIPEF-CI
showed great dedication in financing the rehabilitation of the plantations, mills and site
infrastructure. This has enabled production to be increased to an annual average of 68,000
tonnes of crude palm oil.
The UOC subsequently acquired all the shares in SIPEF-CI and drew up a development
programme for the next five years, including a capital investment of FCFA 15 billion to
continue the site's development and renovation projects.
SIPEF-CI reached a new record at the end of 2020, with an annual production of 72,500
tonnes of crude palm oil.
3. SIPEF-CI
SIPEF-CI (Société Internationale de Plantations et de Finances - Côte d'Ivoire) is a public
limited company with registered offices in Abidjan, Marcory Zone 4C, rue du 7 décembre,
and capital of FCFA 3,072,000,000.
3.1. Activities of SIPEF-CI
SIPEF-CI's main activities are :
 Supervision of village planters ;

 The purchase of palm bunches from Village Plantations (PV) ;
 Management of Industrial Plantations (IP) ;
 Maintenance of the runways and bridges of the Agro-Industrial Complexes (EAI);
 Palm oil and palm kernel production;
 The sale of this production to local (ADAM-AFRIQUE) and external industries.
To carry out its activities, SIPEF-CI, with an estimated 1,900 employees, has three agro-
industrial complexes: the BOLO E.A.I., the OTTAWA E.A.I. and the Okrouyo E.A.I., with
two oil mills located at the BOLO and OTTAWA sites.
As part of our course, we will be focusing much more on the Bolo oil mill.
3.2. Missions of SIPEF-CI
As part of its RESPO certification, SIPEF-CI undertakes to:
 Ensure that its plantations do not contribute to deforestation and that it respects the
environment and biodiversity (no new plantations in primary forests or HCVs)
 To ensure that no children are employed on its plantations
 To help raise the level of education and development of workers and local populations
 Ensuring respect for community cultures and rituals.
In addition to the RESPO certificate, SIPEF-CI has two other certifications: the Halal
certificate and the Jewish certificate.
Appendix 1 shows the RESPO certificate.
3.3. E.A.I de BOLO
The BOLO E.A.I. is located in the province of Sassandra, in the sub-prefecture of Dapkadou.
The site covers an area of around 5,316 hectares, and the plant has a crushing capacity of 60
tonnes/hour. Its operations are directly linked to several plantation owners in the village, who
own a total of 23,000 hectares of plantations. They delivered their products (palm bunches) to
the plant, which opened on 21 June 1971.
Figure 2BOLO site
Figure 3Location of SIPEF-CI BOLO
3.4. BOLO E.A.I. organisation chart
Figure 4BOLO E.A.I. organisation chart
II. Presentation of the end-of-study project
1. Theme title
The subject of our study is entitled: "OPTIMISATION DE LA CENTRALE A
BIOMASSE: CASE DE L'HUILERIE DE BOLO".
2. Specifications
As part of our final year project, we were given the following brief:
 Optimum use of all solid waste from the process to optimise green energy and avoid
over-consumption of other energy sources
 Preliminary study of the biomass to be conserved after the campaign
 Optimising the quality of combustion in the boiler
 Study on the optimum use of the boiler
 Study on the optimum choice of turbine to start up depending on the champagne
periods or requirements
 Economic study of the operation of the boiler/turbine combination (maintenance costs,
labour costs, energy costs, water costs).
PART 2: STUDY OF THE EXISTING SITUATION
I. Crude palm oil production process and principle of biomass

cogeneration
1. Crude palm oil production process

The BOLO oil mill comprises a number of operations aimed at producing crude palm oil and
solid waste (fibres, pressed stalks and husks), which will be used in our PFE. These
operations are: sterilisation, extraction, clarification and palmistry.
NB: We would like to point out that before these various operations, we have the
weighbridge, which is responsible for weighing the fresh bunches entering the factory, which
are then dumped into the hopper. The hopper has 12 doors, each of which can hold up to 15
tonnes of fresh bunches.
1.1. Sterilisation
Sterilisation stops the enzymatic activity of lipases, which cause the oil to become more
acidic, and makes it easier to detach the fruit from the stalk. This operation, which takes place
in the vertically arranged sterilisers (3), which are fitted with two doors (the upper door for
filling and the lower door for emptying) and can each hold up to 30 tonnes of fresh bunches,
is carried out under saturated steam at a pressure of 3 bar (≈130°C) for an average of 75
minutes. The sterilisers are filled via screw conveyors that convey the fresh bunches from the
hopper to the top door of the steriliser.
NB: We would like to point out that there is an old system comprising four (4) sterilisers
which are horizontal metal cylinders fitted with a door and equipped with rails allowing the
introduction of trains of sterilisation cages each containing around 27.5 tonnes of fresh diets.
Appendix 2 describes the cooking cycle for fresh diets in the steriliser.
1.2. Extraction
At the plant, we have two extraction lines comprising a destemmer drum, a mixer, a press, a
sand tank, a secondary tank, a primary tank, an extraction sieve and a buffer tank.
 There are two (2) destemmer drums (one for each chain), which separate the fruit from the
stalk by rotating at reduced speed. The bunches are rotated up to the highest point of the
destemmer, from where they fall onto the bars of the cage, between which the fruit
escapes. The bunches rise and fall several times as they make their way to the exit of the
drum, where they become stalks, in principle devoid of fruit. These stalks are then
conveyed by a screw to the stalk presses, which produce pressed stalk fibre for use as fuel
in the boiler. A screw under the destemmer drum conveys the fruit to the washing sieve,
which then reaches the fruit lift that feeds the mixers using another screw conveyor.
 We have three (3) mixers on each extraction line, giving a total of 6 mixers for mechanical
and thermal preparation of the fruit prior to pressing. The mass of fruit is heated to a
certain temperature and then subjected to the mechanical action of the mixing arms. This
dual action dilacerates the fruit pulp and releases the palm oil.
 The press (3 presses for each extraction line) extracts the raw juice from the mass of
mixed fruit; this operation takes place in the screw presses. In the presses, the mass of
mixed fruit is driven by two screws turning in opposite directions inside a perforated cage,
the outlet of which is partially blocked by two adjustable cones (thus slowing down the
outflow of material). The pressure generated in the cage extracts the raw juice, a mixture
of oil, water and solid impurities contained in the mass. The raw juice is diluted in the
press by simply adding hot water. At the press outlet, two separate products are collected:
the raw juice, which is conveyed to the sandbox, then to the raw juice tank, is redirected to
the extraction sieve using centrifugal pumps and is then conveyed to the buffer tank and
clarification, and the palm cake (a mixture of fibres and nuts) conveyed to the defibrator
by a crushing screw, which separates the fibres from the nuts. The collected fibres are
conveyed to the boiler and the nuts are conveyed to a polishing drum which, by friction,
removes the last adhering fibres. These are also sucked into the defibration column.
1.3. Clarification
The crude juice obtained after sieving is heated in the boiling column to break the bonds
between the oily and non-oily molecules and homogenise the crude juice. Next, the primary
decanter separates the oil from the sludge and recovers it through a strainer before partially
dehydrating it in the pre-dehydrator. The secondary decanter precipitates impurities from the
oil to the bottom of the decanter for better dehydration, and the oil heater heats it to a
temperature of between 105°C and 110°C. The moisture content of the oil must be reduced to
less than 0.2%. After heating, the oil is dehydrated in the natural dehydrator and the sludge is
heated to 90°C in the sludge tank. The purpose of heating the sludge is to break down the
molecular bonds in the sludge and then send it to the sludge buffer tank, which in turn
provides a regular feed to the three-phase decanter, which is responsible for dynamically
separating the light sludge into three phases in order to recover as much of the oil contained in
the sludge as possible. The finished crude oil is collected in finished oil tanks and conveyed to
the storage tanks by centrifugal pumps.
1.4. Palmisteria
The palmisteria is currently under construction and is scheduled for delivery in November
2023.
NB: Palm kernels are used as fuel.
The diagram below shows the production process for crude palm oil at the BOLO oil mill.
2. Principle of biomass cogeneration

Cogeneration is defined as the simultaneous production of two forms of final energy from a
single primary energy source in a single installation. The production of heat (steam) and
electricity from solid biomass is considered one of the main alternatives for sustainable
development.
At our power station, heat and electricity are cogenerated from fibres, ship hulls and other
debris from the production process.
2.1. Schematic diagram of biomass cogeneration .
Superheated
steam Alternator
Biomass fuels Biomass
Turbine A Electricity
boiler
Saturated steam
Feed water Low-pressure storage Process

tank
Figure 5Principle of biomass cogeneration
2.2. How it works
The fuel used is biomass, made up largely of fibres, hulls and production waste. Cogeneration
begins with combustion of the biomass in the boiler. The steam obtained during combustion is
fed into the turbine, which, thanks to the alternator, produces electricity to power the plant
and its distribution network, and some of the steam is used in the plant's process.
II. General description of the biomass plant and other energy

sources
1. Description of the biomass power plant
Figure 6Operating diagram of the biomass power plant
2. Boiler
2.1. Description
The
SIPEF-CI Bolo oil mill has a BOILERMECH SDN.BHD boiler, type BMWT 0680, with
water tubes and two (2) tanks, using solid fuels made up of fibres, husks and debris from palm
Figure 7Boiler illustration diagram

oil production. It produces superheated steam at 22 bars and 270°C at a rate of 30 tonnes per
hour.
Figure 8Schematic diagram of the BoilerMech boiler at the factory
2.2. Boiler components
Conveyors
Equipment Types Quantit Roles

y
Transporting fuel from the polishing drum to
Cladding screws Geared motor 4 the boiler
Fibre elevator Geared motor 2 Feeding the boiler with fibre
Horizontal fibre Receives fuel from the lift and the cladding
Geared motor 2
conveyor screws, then makes up for it at the boiler.
Screw in front of Receives fuel from the defibrator and feeds
Geared motor 1
boiler it into the cladding screws
Table 1:Characteristics and roles of conveyors
The draw
Equipment Type Quantity Role
Carries heat, ash and debris

Drawing Engine 1
to the chimney
Table 2:Characteristics and roles of the draw
The locks
Equipment Types Quantity Roles

Lock 1 Engine 1 Regular cleaning of boiler
ash and debris
Lock 2 Geared motor 1
Table 3Characteristics and roles of locks
Air supply

Blowing, activating the fire
Primary air Engine 1
in the fireplace
Secondary air 1 (air Project the fibres inside the
Engine 1
blower) fireplace
Create a swirl of fibres
Secondary air 2 Engine 1
with the air at the hearth
Regulate the air coming
Air distributor Geared motor 1 from the air blower using
its vanes
Manage the air needed to
feed the boiler, automatic
Air compressor Engine 1
valve opening
Table 4Characteristics and roles of air supply units
Water supply

Food pumps Engine 2 Continuously supply the
boiler with water from the

feed tank
Feed tank recovery Collect the water from the
Pump motor 1
pump 1 food tarpaulin, convey it to
Feed tank recovery the deaerator and return it to
Pump motor 1
pump 2 the tarpaulin.
Dosing pumps Inject flocculant, coagulant
(flocculant, lime, Pump motor 3 and lime products into the
coagulant) water being treated
Table 5Characteristics and roles of water suppliers
Other components
Equipment Quantity Role

Food tarpaulin 1 Used to store boiler feed water. It has a capacity of
100 m3
Fireplace 1 Removes heat, ash and debris
Filled with 50% steam - 50% water, it acts as a
Upper balloon 1 water collector and enables vaporisation (for the
production of saturated steam).
Collects the water supplied by the pumps and feeds
Lower balloon 1
it into the boiler pipes
This is the valve that allows the steam produced to
Head valve 1
be sent to the turbine.
Superheater 1 Raises the temperature of the steam
Drain valves (6
for manifolds and
8
2 for bottom Cleaning product deposits from pipes
extraction)
Mobrey 1 Water level sensor (low, normal, high, very high)
Solenoid valve 1 Automatic regulator for water entering the boiler
Allows you to start/stop the various components of
Control room 1 the boiler, monitor its pressure build-up, monitor
the various boiler parameters, etc.
Table 6Roles of other boiler components
Water treatment
To prevent scaling, corrosion and foaming, and to produce a better quality of steam, the water
is treated before being used by the boiler. The treatment is carried out in two stages: the actual
treatment at the water supply station and the conditioning in the feed tank.
 Raw water treatment
When the water is pumped from the river, its pH is measured and then it is pumped through
the pipes by adding the flocculant, coagulant and lime. The coagulant brings together the
organic matter in the water. The flocculant in turn forms the organic matter into blocks, and
the lime raises the pH of the water. After injecting these products into the pipes, the mixture
arrives in the reaction tank where the products mix and then pass through the decanter where
the blocks formed settle to the bottom and the water obtained is sent to the clear water tank.
 Packaging in a food tarpaulin
The clear water obtained at the end of the actual treatment is sent to the feed tank after being
injected with softeners such as erpamousse, synerpon and nalcopulve-19. These softeners
remove the magnesium and calcium responsible for limescale formation.
The treated water is stored in the feedwater tank for use by the boiler and for plant
maintenance operations.
The technical characteristics of the BOILERMECH SDN.BHD boiler are given in Appendix
3.
2.3. How it works
The water in the water and steam tank comes from the feed tank, where it has been chemically
treated beforehand. The water in this tank is heated (105°C). From the upper tank, this water
flows through the drop tubes to reach the lower collectors (collectors to which several steam
tubes are connected). As these tubes receive the heat released by the combustion of the fuel
(fibres, hulls and debris), the temperature rises and the density of the water decreases. This
water then circulates (thermosiphon principle) towards the upper drum via the upper
collectors. At this point, the saturated steam (22 bar/219°C) separates from the water,
occupying the free space in the tank. The water then flows back into the headers for another
cycle of vaporisation. The saturated steam is superheated in a superheater via a spigot at the
top of the upper drum. It is this superheated steam (20-22 bars/270°C) that is sent via a
manifold to the various turboalternators.
3. The power station
3.1. Turbo generator
The BOLO oil mill has four (4) turboalternators for the production of electricity. The steam
turbines in these turbo-alternators are single-wheel (single-stage) "back-pressure" machines.
This back pressure is characterised by the fact that not all the energy contained in the steam
entering the turbines is used by them. Some of the superheated steam is deliberately extracted
from the turbine exhaust to be used in the diet process (sterilisation, drying, etc.). This is why
the steam is desuperheated in a low-pressure vessel, where it comes out saturated (2.5-3
bars/130°C), thus facilitating heat exchange. Each turbine is coupled to a mechanical gearbox
that reduces the speed of rotation of its shaft (6,000 to 7,000 rpm) so that it can drive the
alternator shaft at a speed of 1,500 rpm. Alternators convert mechanical energy into electrical
energy, which is then sent to the power station to be dispatched to meet demand (factories,
homes, etc.).
The technical characteristics of the various turbo-alternators are given in Appendix 4.
The diagrams below show the various turbo-alternators (TA):
Figure 9View of the TA
3.2. Generator set
The BOLO oil mill has a KOHLER SDMO generator set. The purpose of this generator is to
 Act as a back-up unit to ensure power availability.
The electrical energy supplied by this generator also reaches the power station where it is
synchronised with that supplied by the turboalternators. The technical characteristics of the
generator set are given in Appendix 5.
The diagram below shows the generator set:
Figure 10:Generator visual
3.3. CIE
In the case of the plant, we have a connection to the CIE system with a subscribed power of
630 kW and a 1000 kVA transformer, which allow us to :
 Start-up of plant units

 To ensure the production of electricity when the plant is shut down or when the loads
on the electricity grid are too high for the turbo-alternators.
III. Analysis of the fuel used

The Bolo oil mill uses solid waste from the processing of palm bunches as fuel for the boiler
furnace. This fuel is made up of fibres, hulls, fibres from pressed stalks and debris (small
pieces of dried hulls, traces of broken kernels, etc.). The respective proportions of these
components for a fresh diet are given in appendix 6. The furnace of the boiler is supplied
with fuel by means of feed screws filling the various spouts. Excess fuel is conveyed by the
same feed screws to the storage shed, where it is reintroduced into the feed circuit via the fuel
lift.
1. Elemental mass composition of fuel components

The elemental mass compositions of the various components of the fuel currently used are
given in the following table:
Fibres Shells Scrap

Carbon (c) 46,8 53 53
Hydrogen (h) 6,6 6 6
Oxygen (o) 41,7 38,6 38,6
Suffering (s) 0,4 0,4 0,4
Ash (d) 4,5 2 2
Table 7Fuel composition by mass
2. Fuel characteristics
The main characteristics of the fuel are :
- the moisture content w (%H 2 O), which is important for determining the lower calorific
value of the fuel,
- mass composition, which tells us the proportion of each component in a fuel mixture,
- the net calorific value (NCV), which defines the energy value of the fuel, or the quantity of
heat that can be released when one unit of mass (or volume) of the fuel is completely burnt
under normal conditions of temperature and pressure.
2.1. Humidity level
The following are the results of analyses carried out by the plant's laboratory over the period
January 2023/June 2023 on the moisture content of the fuel used to produce steam.
MONTHS Fibres Shells Scrap

January 2023 40,74 12 12
February 2023 39,46 12 12
March 2023 38,06 12 12
April 2023 37,27 12 12
May 2023 37,62 12 12
June 2023 37,39 12 12
Table 8Moisture content of fuel
2.2. Mass composition
Determining the mass composition of the fuel essentially enables its weighted ICP to be
calculated. To achieve this, various fuel samples are taken, weighed and then sorted manually
to separate fibres, hulls and debris. The components separated by classification are weighed
again to determine their mass ratio in the mixture.
2.3. Lower calorific value (LCV)
The net calorific value (NCV) of a fuel (fibre, hulls or debris) depends on its gross calorific
value (GCV), its moisture content (%H2 O) and its hydrogen content (%H2 ). The GCV is
determined using the following formula:
PCS ( 100−w )−600 (w+ 9 h)

PCI= (kcal/kg)
100
Knowing that the PCS=8100 c+29000 (h−o/8)+2500 s in kcal/kg for solid fuels.
As the fuel used is a mixture of three (3) fuels with different mass proportions, its weighted
PCI should be determined using the PCI formula.
3
Thus, we have : PCI pondéré =∑ PCI combj∗%combj
j =1
PCIcomb j : PCI of fuel j
%comb j: mass proportion of fuel j in the fuel mixture.
The table above gives the ICP values for each fuel and the weighted ICP based on analyses
carried out on fuel samples taken to determine its mass composition:
Month Fuel Mass composition PCS PCI Weighted PCI
Fibre 86,47 4203,175 1889,96151 2133,5

Jan 23 Hull 12,94 4643,75 3690,5 7
Scrap 0,59 4643,75 3690,5
Fibre 88,12 4203,175 1951,44215 2158,0
Feb-23 Hull 11,05 4643,75 3690,5 4
Scrap 0,83 4643,75 3690,5
Fibre 85,23 4203,175 2018,6866 2265,6
March 23 Hull 14,21 4643,75 3690,5 1
Scrap 0,56 4643,75 3690,5
Fibre 86,47 4203,175 2056,63168 2277,6
Apr-23 Hull 12,94 4643,75 3690,5 9
Scrap 0,59 4643,75 3690,5
Fibre 88,12 4203,175 2039,82057 2235,9
May 23 Hull 11,05 4643,75 3690,5 2
Scrap 0,83 4643,75 3690,5
Fibre 85,23 4203,175 2050,86787 2293,0
June-23 Hull 14,21 4643,75 3690,5 4
Scrap 0,56 4643,75 3690,5
Table 9ICP values for each fuel and weighted ICP for each month
We were therefore able to determine the average ICP of the fuel, which is the average of the
weighted ICPs:
Average ICP = 2227.31

kcal/kg
IV. Analysis of the amount of fuel and steam consumed by the

boiler
1. Calculating the ratio kg vap /kg comb
To determine the ratio kg vap /kg comb :
 To calculate the energy required from the incoming biomass, apply the following
ṁvap (hvap −heau )
formula: Q̇biomasse =
ηChaudière
Knowing that ηChaudière =73 % and ṁvap =30 t/h
30000∗(2942 , 05−438 , 9)
Numerical application: Q̇biomasse= =102869178 kJ /h
0 , 73
Q̇biomasse=102869178 kJ /h
 We will calculate the biomass mass flow rate by applying the following formula:
Q̇biomasse
ṁcomb=
PCI biomasse
102869178
Numerical application: ṁ comb= =11049 ,13 kg /h
9310 , 16
ṁcomb=11,049 t/h
The ratio kg vap /kg comb is therefore :
ṁvap 30
= =2 ,71 kg vap /kg comb
ṁcomb 11,049
ṁvap
=2, 71 kg vap /kg comb
ṁcomb
2. Current fuel situation

Based on the quantity of diets processed and the quantity of steam produced per month over a
period of 6 months, we determine the forecast quantity of fuel:
Forecast quantity of fuel = 12% Quantity of bunches processed + 7% Quantity of bunches

processed
This relationship is due to the fact that a fresh diet contains 12% fibre and 7% hulls
(appendix 6).
We will then determine the quantity of fuel consumed by the boiler, knowing the boiler's
steam production over the same period and the ratiokg vap /kg comb.
The table below shows the various results:
Month Jan 2023 Feb 2023 March Apr 2023 May June Total over
2023 2023 2023 the period
Quantity of 12 20 35 32 25 14 140
fresh 904,32 651,92 106,82 650,20 105,52 341,70 760,48
bunches
processed
(Tonnes)
Quantity of
steam 8619,59 9752,43 16488,7 16765,8 11052,8 9482,60 72161,92
produced
(Tonnes)
Quantity of
fuel
produced 2451,82 3923,86 6670,30 6203,54 4770,05 2724,92 26744,49
(Tonnes)
Quantity of
fuel
consumed 3180,66 3598,68 6084,39 6186,64 4078,52 3499,11 26628
by the boiler
(Tonnes)
Table 10Amount of fuel consumed by the boiler
We have noticed that the plant has a shortage of fuel in some months, so to make up for this
we use pressed cob fibre, which accounts for around 8% of the quantity of fresh bunches
processed.
V. Analysis of the specific consumption of turbo-alternators and

breakdown of production and consumption of electrical
energy
1. Specific consumption of turbo-alternators
The table below shows the specific consumption of the turbo-alternators kg comb /kWh from
January 2023 to June 2023 :
Data available in
monthly industry March April
reports Jan 2023 Feb 2023 2023 2023 May 2023 June 2023
Quantity of fuel
consumed by the 3180,66 3598,68 6084,39 6186,64 4078,54 3499,11
boiler (T)
Energy produced by
258 411 263 715 387 096 546 429 435 514 312 092
turbines (kWh)
Specific
consumption of TA 12,31 13,65 15,72 11,32 9,37 11,21
(kg/kWh)
2. Breakdown of electricity production and consumption

The table above shows the electrical energy produced by the power plant (turbo generator,
genset, ICE) and consumed by the plant from January to June 2023.
Table 11Specific consumption of turbo-generators

Data available in March

monthly industry reports Jan 2023 Feb 2023 2023 April 2023 May 2023 June 2023
Energy produced by
258 411 263 715 387 096 546 429 435 514 312 092
turbines (kWh and %)
Energy produced by the

710 7 703 2 896 1 003 4 318 1 152
generator (kWh and %)
Energy supplied by CIE

77 384 91 122 188 148 25 494 48 906 46 252
(kWh and %)
Energy consumed by the

336 505 362 540 578 140 572 926 488 738 359 496
plant (kWh)
The table below shows the breakdown of energy produced by the power plant over 6 months.
Table 12Electrical energy produced by the power station and consumed by the plant
Breakdown of energy produced by the power

plant
600,000
546,429
500,000
435,514
387,096
400,000
312,092
300,000 258,411 263,715
188,148
200,000
91,122
77,384
100,000
48,906 46,252
25,494
710 7,703 2,896 1,003 4,318 1,152
0
Jan-23 Feb-23 Mar-23 Apr-23 May-23 Jun-23
Energy produced by turbines (kWh) Energy produced by the generator (kWh)

Energy supplied by CIE (kWh)
Figure 11Breakdown of energy produced by the power plant
VI. Boiler energy balance
1. Method for calculating boiler performance indicators
1.1. Efficiency on PCI
The PCI efficiency is the performance indicator for the boiler's energy production. This value
tells us how well the boiler is working, so we can better appreciate its performance.
1.2. PCI
By analysing the fuel, which is a mixture of fibres, hulls and debris, we have determined the
average ICP of this fuel over a given period and its value is :
ICP = 2227.31 kcal/kg PCI=9310.16 kJ/kgcomb
1.3. Estimating heat loss
According to the heat balance, PCI=Q utile +Q perdue(in kJ/kg)
With :
PCI = Energy available per unit of fuel
Qutile = Useful energy
Q perdue= Energy lost
The various losses observed in the boiler are :
 Wall losses (q ext )
These losses are not measurable. They will be estimated as a certain percentage of the ICP.
So we have : q ext =4 % PCI
 Unburned losses (q imb)
As these losses cannot be measured in the flue gas, they will also be estimated as a percentage
of the ICP : q imb =3 % PCI
 Stack losses (q ch)
To determine the losses through the chimney from the flue gases, we will use the following
k (T ch−T a)
approximate formula: q ch= ∗PCI (SIEGERT formula)
%(CO 2 +SO2 )
With :
k = coefficient depending on the elemental analysis of the fuel
Tch = Flue gas temperature in °C
Ta = Air temperature in °C
% (CO2 + SO2 ) = Results of flue gas measurement
The measurement of CO2 and SO2 is carried out by an SGS team that makes visits to ensure
the environmental compliance of the various SIPEF-CI oil mills. The latest SGS report gives
the following results: % CO2 =13.8 and %SO =02
 Water losses through draining (q purge)
Water losses are calculated using the following formula:q purge=τ purge∗heau
with :h eau=Cpeau∗T eau (Cpeau = 4.18 kJ/kg °C and T eau= 105°C)
Taking into account the monthly values, we will determine the average purge rate from
January 2023 to June 2023.
Month Jan 2023 Feb 2023 March Apr 2023 May 2023 June Average
2023 2023
Purging
rate (%) 4,45 4,78 5,99 4,53 4,63 5,98 5,06
Table 13Bleed rate
 Steam and other losses (q vap)
The heat balance at the boiler gives us :
PCI=Q utile +Q perdue (in kJ/kg)
The energy lost is equal to the sum of the energy losses in the boiler.
Q perdue =q ext + qimb +q ch +q purge +q vap
Therefore : PCI=qext +q imb + qch + q purge + qvap +Qutile (in kJ/kg)
To determine steam losses, we first determine the useful energy.
ṁvap
Qutile = (h −h )
ṁcomb vap eau
The enthalpy of the steam will be determined by interpolation using thermodynamic tables
and fluid properties.
Determining the useful energy therefore allows us to deduce the expression for steam losses:
q vap=PCI −¿)
ṁvap
Let R= the steam production ratio with :
ṁcomb
ṁvap the steam flow produced
ṁcomb the fuel flow rate consumed
2. Results
2.1. Calculating losses
 Wall losses (q ext )
4∗9310 , 16
Numerical application: q ext = =372 , 41 kJ /kg
100
q ext =372 , 41 kJ /kgcomb
 Unburned losses (q imb)
3∗9310 , 16
Numerical application: q imb = =279 , 31 kJ /kg
100
q imb =279 ,31 kJ /kg comb
 Stack losses (q ch)
k (T ch−T a)
q ch= ∗PCI
%(CO 2 +SO 2 )
k=0.74 for hulls and wood
k = 0.74 for hulls, wood
Tch = 270°C
Ta = 30°C
%CO2 = 13.8
%SO2 = 0
0 , 74(270−30)
Numerical application:q ch= ∗9310 , 16=1198, 18 kJ /kg
13 , 8∗100
q ch=1198 ,18 kJ /kg comb
 Water losses through blowdown (q purge)
q purge=τ purge∗heau with (h ¿ ¿ eau=Cp eau∗T eau)¿
Numerical application: h eau=4.18∗105=438 , 9 kJ /kg
q purge=0,0506∗438 , 9=22 , 21 kJ /kg

q purge=22 , 21 kJ /kgeau
 Steam and other losses (q vap)
ṁvap
The ratio kg vap /kg comb has the value : =2, 71 kg vap /kg comb
ṁcomb
ṁvap
Qutile = (h −h )
ṁcomb vap eau
Let's determine h vap et heau
According to the thermodynamic table, at 22 bar and 270°C, we have :
h vap=2942 , 05 kJ /kg vap
Numerical application: Qutile =2 ,71∗( 2942 ,05−438 ,9 )=6783 , 54 kJ /kg
We therefore deduct the value of steam and other losses :
q vap=9310 ,16−( 372 , 41+279 , 31+1198 , 18+22 , 21+ 6783 ,54 )=kJ /kg
q vap=654 , 51 kJ /kg
2.2. Calculating apparent boiler efficiency
The apparent efficiency of the boiler is given by :
Qutile
η a= ∗100
PCI
6783 ,54
Numerical application: η a= ∗100=72 , 86 %
9310 ,16
η a=72 ,86 %
2.3. Analysis and interpretation
The energy balance above shows that the boiler's efficiency is approximately equal to the
manufacturer's efficiency (η constructeur =73 % ¿. This is justified by the fact that the BM boiler
was commissioned in June 2022.
However, there are a number of bad practices that can affect the correct operation of the
boiler. In the rest of our work, we will identify these various causes using the Ishikawa
diagram and make recommendations for optimum operation of the MB boiler.
PART 3: OPTIMISING THE BIOMASS POWER

PLANT
I. Optimum boiler operation
1. Ishikawa diagram
1.1. Definition
The cause-effect diagram or ISHIKAWA diagram or 5M method (material, manpower,

material, methods and environment) is an approach that identifies the possible causes of a
problem or defect:
 Materials: the materials used, and more generally their contribution to the process;
 Materials: equipment, machinery, IT hardware, software and IT technology;
 Methods: Operational methods, process logic and research and development activities;
 Labour: employees, human intervention ;
 Milieu: setting, environment, location, context.
To better assess the parameters that directly or indirectly weaken the operation of BM boilers,
we will use the Ishikawa diagram, created from our observations and surveys of operators and
managers.
1.2. Presentation of the Ishikawa diagram
MATERIA MATERIAL
L No maintenance of boiler
Wet fuel used wet
components
Sometimes using the No fuel flow

wrong fuel regulator
Clinker formation
Nuts and pressed cob fibre
used Use of wet fuel NON-OPTIMAL
OPERATION OF THE
BOILER
Troubleshoo
ting Qualification Nois
Poor e
maintenance Inadequate Difficult
Unmotivated
management training communication and
staff
Insufficient the danger of hearing Environment
No scheduled preventivestaff loss
maintenance No performance
bonus Hot
METHOD WORKFORCE ENVIRO
NMENT
1.3. Explanation of the diagram
The diagram reveals the following malfunctions:
 Material
The fuel used in the boiler is too moist. It sometimes contains materials that are not
recommended for the boiler, such as nuts and pressed cob fibres. The material used therefore
has a negative impact on the operation of the boiler. It is the cause of the presence of unburnt
particles in the chimney. Because of its humidity, it consumes too much fuel, which is
contrary to the desire to consume less and produce more.
 Hardware
The equipment needed to operate the boiler is not maintained. Equipment such as water
supply pumps, air compressors and draught fans need to be properly maintained to avoid
pressure drops or low water levels. In addition, the absence of a fuel flow regulator leads to
excessive fuel consumption. Finally, the formation of clinker due to the moisture contained in
the fuel reduces heat transfer in the boiler.
 Method
Although maintenance work is carried out if the motors or other boiler equipment
malfunctions, a regular preventive maintenance programme has not been established to carry
out various checks in accordance with the manufacturer's instructions. This often leads to
breakdowns that affect production.
 Workforce
Boilers are technological elements, and knowledge of the various operations to be carried out
is extremely important. There is a lack of training and insufficient staff, and sometimes even a
drop in motivation among the operatives who work on various pieces of equipment such as
fuel lifts and boilers. These various reasons are at the root of pressure drops in the boiler.
 Environment
Communication at production level is difficult because of the noise from equipment in

operation. This has serious consequences for workers' health, particularly in terms of hearing
damage. The environment is hot and lacks maintenance.
Analysis of the ISHIKAWA diagram shows that a number of factors are responsible for the
boiler's non-optimal operation.
It should also be pointed out that poor-quality fuel is a source of many inconveniences:
 Muffling the fire

 Release of black fumes
 Large quantities of unburnt fuel are discharged down the chimney
 Frequent clogging of grilles and flue gas ducts
 Sealing of primary and secondary air circuits
 Premature wear of exhaust fans
 Excessive fuel consumption
2. Recommendations
The Ishikawa diagram enabled us to highlight and unseal the factors that were causing the
boiler to operate sub-optimally. Firstly, we will draw up a list of proposals to be taken into
account to improve the quality of the fuel, thus avoiding over-consumption of fuel. Secondly,
we will carry out a detailed study of the system, which will enable us to determine the ratio
value kg vap /kg comb.
The following ideas are proposed to reduce boiler breakdowns and pressure drops.
RECOMMENDATION IMPLEMENTATION RESULTS
Better monitoring of steam Installation of metering equipment

and fuel consumption (fuel meter)
Carry out regular chimney Enable boiler
Efficient fault management sweeping operations performance to be
Implementation of a maintenance assessed and avoid
management system breakdowns and pressure

drops
Reduce heat loss due to
No use of unsuitable fuel Avoid using nuts and fuel that is clinker formation
too damp for combustion
Reduce the amount of
Reduction in fuel moisture fuel consumed by the
Installation of a dryer boiler
Operator training Organise regular training for Avoiding incorrect

operators, especially new ones equipment settings
Table 14Suggested ideas for optimum boiler operation
II. Optimising combustion quality in the boiler and fuel storage
1. Fuel quality
The factor that negatively influences the quality of combustion in the boiler is the moisture
content of the fuel used.
It is a well-known fact that the calorific value of fuel decreases as the moisture content
increases. The moisture content of the fuel will therefore have a direct impact on the operation
of the boiler, which may shut down completely after receiving wet fuel. Therefore, by
reducing the amount of water in the fuel, we increase the PCI of this fuel and the ratio
kg vap /kg comb of the boiler.
2. Fuel drying
In the oil palm industry, in addition to economisers and air heaters, there is a third way of
improving the combustion process in the boiler furnace, which consists of drying the fuel
leaving the conveyors before sending it to the boiler. This process has the great advantage of
bringing the flue gas fumes to the lowest possible temperature, thus helping the appliance to
better recover heat from the flue gas. The temperature of the gases leaving the boiler depends
on many different factors, not least the moisture content of the fuel. Since the lower the
temperature of the gases leaving the chimney, the higher the efficiency, humidity must be
taken into account and is of great importance in the process.
The diagram shows the influence of moisture on the PCI of the fuel:
Influence of humidity on PCI

4000
3441.162
3500 3198.053
2954.944
3000 2711.835
2468.726
ICP (Kcal/kg)
2500 2225.617
1982.508
2000
1500
1000
500
0
5 10 15 20 25 30 35 40 45
Humidity (%)
Figure 12Influence of humidity on PCI
It can be seen that the PCI falls sharply as the moisture content of the fuel increases. So to
increase the boiler's kg vap /kg comb of the boiler, which depends on the ICP of the fuel, it is
necessary to reduce the moisture content. Our aim is to reduce the moisture content of this
fuel to 10%. This will enable us to increase its ICP and the ratio kg vap /kg comb ratio, thereby
reducing the amount of fuel consumed by the boiler.
 Calculation of the kg vap /kg comb optimal
At 10% humidity, the average PCI of this fuel is : PCI=14384.05 kJ/kg comb
Knowing that Q̇biomasse=102869178 kJ /h
Q̇biomasse 102869178
We then have ṁcomb= = =7 , 15t /h
PCI biomasse 14384 , 05
ṁvap 30
So the ratio is kg vap /kg comboptimal is : = =4 , 20 kg vap /kg comb
ṁcomb 7 , 15
ṁvap
optimal=4 ,20 kgvap /kgcomb
ṁcomb
So, for a steam flow of 30 t/h and a ratio of 4.20, we will have an average fuel consumption of
7.15 t/h. It is therefore useful to study the possibilities available to us for reducing humidity,
and dryers are one such solution. Another advantage of the dryer is that the fuel entering the
boiler is heated, which facilitates combustion and rapid ignition of the boiler.
In the literature and in numerous scientific publications, researchers have mentioned the
possibility of using flue gas smoke to dry the fuel and thus increase its calorific value.
In the case of our installation, the temperature of the flue gas escaping through the chimney is
between 2000 C and 3000 C. Consequently, our selection of dryers will be based on this
technology.
3. Dryer sizing
The aim of our study is to design a dryer capable of continuously processing 10,000 kg of fuel
every 3 hours.
3.1. Summary of the sizing method
To size our dryer, we need to know the data given in the table below:
Products: fibres, palm shells - Initial humidity: 40%

- Final humidity: 10%.
Ambient air : - initial dry and wet temperature:

800 C / 54.80
C - initial
relative humidity: 50%.
- initial absolute humidity:
102.426 g/kg airsec
Drying conditions imposed by the upstream and downstream - mass of products to be dried:
sectors. 10,000 kg
- drying time: 3 hours
In what follows, we will have to determine the elements below and choose the dryer that
meets these criteria:
 Mass of water to be extracted : M e =(mi −mf )M i in (kg)
With :
miInitial water content of fresh product (in %) ;
mf Final water content of the dried product (in %) ;
M eQuantity of water to be extracted from the product (in kg) ;
M iQuantity of fresh product to be dried (in kg).
Me
 The speed at which water is removed from the product : V em = in (kg eau /h)
TS
With :
M eMass of water to be extracted (in kg) ;
T SIdeal drying time for the product in question (in hours).
100∗V em
 The air flow rate through the dryer : D s =
ρair∗( x m−x a )∗η s
With :
Ds Air flow rate required (in m3 /h) ;
V em water removal rate (kg/h) ;
ρair Density of dry air: 1.2 kg/m3 ;
x mWater content of the air leaving the dryer, averaged over the drying time, in g/kg airsec ;
x aWater content of the air at the dryer inlet, in g/kg airsec ;
η sDrying efficiency.
Me
NB: we have η s=
Mi
 Drying temperature
The permissible temperature for drying palm fibres and shells is 100 0 C. You can therefore
refer to the drying tables for fibrous materials to find out the drying temperature.
In our case we have T =80s0 C and Th =54.8 C0
With Ts and Th successively the dry and wet air temperatures inside the dryer.
To determine x mTo determine the water content of the air leaving the dryer, the evaporation
capacity of the drying air must be known. This evaporation capacity is determined as a
function of the humidity and temperature of the ambient air and its value is E a=5 .
Ea
Thus, we have : x m= + x a=104,926 g/kg airsec
2
3.2. Results
 The body of water to be extracted :

AN : M e =( 0 , 4−0 , 1 )∗10000=3000 k g
M e =3000 kg
 The speed at which water is removed from the product :

3000
AN : V em = =1000 kgeau /h
3
V em =1000 kg eau /h
 The air flow rate through the dryer :

1000∗1000 3
AN : Ds = =11111, 11m /h
1 , 2∗( 104,926−102,426 )∗30
3
Ds =11111, 11m /h
3.3. Choice of dryer
Technically, we chose the Wyssmont TURBO-DRYER because it met all our dimensioning
criteria. The TURBO-DRYER mechanism consists of a stack of slowly rotating circular
plates. The product is introduced onto the shelf above. After one rotation, the product is
pushed towards the lower shelf, where it is mixed, levelled and returned to the lower tray.
This process is repeated throughout the operating period. The trays are placed in an enclosure
where gas or hot air is circulated by an internal fan.
This device enables the product to be dried uniformly, redistributed periodically by a piston
flow mechanism. Thanks to perfect temperature uniformity or the possibility of defining
several temperature zones, turbo dryers offer the most precise temperature control for the
entire drying line. Withstanding temperatures of 600°C, the dryer is equipped with a precise
temperature and drying time control mechanism, enabling you to automatically obtain the best
drying conditions.
The technical specifications of the TURBO-DRYER are given in Appendix 7.
Figure 13View of the dryer
Figure 14descriptive diagram of the dryer
4. Fuel storage
The table shows the different results after installation of the dryer:
Humidity (%) Ratio Fuel Fuel Fuel stored

kg vap /kg comb production consumption after
over the period over the period campaign (t)
(t) (t)
Current 40 2,71 2 6744,49 2 6628 116,49
situation
Dryer 10 4,20 2 6744,49 17 181,41 9 563,08
installation
Installing the dryer will significantly increase our fuel stock, which currently stands at 116.49
tonnes, to 9,563.08 tonnes after the campaign (January 2023 to June 2023). This will enable
us to make up the shortfall in fuel during the off-peak period (July to December).
III. Optimising biomass energy production compared with other

energy sources
On the basis of the various results established previously, we have determined the distribution
of biomass energy via the turboalternators in relation to the other energy sources (CIE,
generator) with the installation of the dryer.
Thus we have :
 For the month of January 2023 :
Knowing that C= 12.26 kg/kWh and the quantity of fuel that will be stored after installation
of the dryer is 400 tonnes, we can produce 32,626.42 kWh more:
Current situation Dryer installation

TA (kWh) 258 411 (76,79%) 291 037,42 (86,49%)
CIE (kWh) 77 384 (23%) 44 047,58 (13,51%)
GE (kWh) 710 (0,21%) 0

Plant consumption 336 505 (100%) 336 505 (100%)
 For the month of February 2023 :
of the dryer is 1,601.86 tonnes, we can produce 98,825 kWh more and keep 390.27 tonnes.
This gives us :

TA (kWh) 263 715 (72,74%) 362 540 (100%)
CIE (kWh) 91 122 (25,13%) 0
GE (kWh) 7 703 (2,15%) 0
 For the month of March 2023:
of the dryer is 2,744.42 tonnes, we can produce 191,044 kWh more and keep 402.22 tonnes.
This gives us :

TA (kWh) 387 096 (66,96%) 578 140 (100%)
CIE (kWh) 188 148 (32,54%) 0
GE (kWh) 2 896 (0,5%) 0
 For the month of April 2023 :
of the dryer is 2,211.68 tonnes, we can produce 26,497 kWh more and store 1,886.83 tonnes.
This gives :

TA (kWh) 546 429 (95,38%) 572 926 (100%)
CIE (kWh) 25 494 (4,45%) 0
GE (kWh) 1003 (0,17%) 0

 For the month of May 2023:
Given that C= 12.26 kg/kWh and the quantity of fuel that will be stored after installation of
the dryer is 2,138.43 tonnes, we can produce 53,224 kWh more and store 1,485.90 tonnes.
This gives us :

TA (kWh) 435 514 (89,11%) 488 738 (86,49%)
CIE (kWh) 48 906 (10%) 0
GE (kWh) 4 318 (0,89%) 0

 For the month of June 2023:
Given that C= 12.26 kg/kWh and the quantity of fuel that will be stored after installation of
the dryer is 467.16 tonnes with 114.01 tonnes, an additional 47,404 kWh can be produced.

TA (kWh) 312 092 (86,81%) 359 496 (100%)
CIE (kWh) 46 252 (12,87%) 0
GE (kWh) 1 152 (0,32%) 0

The quantity of fuel remaining in stock over the period January 2023/June 2023 will therefore
be 4,051.21 tonnes.
 Over the period January 2023/June 2023, we have :

TA (kWh) 2 203 257 (81,65%) 2 654 297,42 (98,37%)
CIE (kWh) 477 306 (17,69%) 44 047,58 (1,63%)
GE (kWh) 17 782 (0,66%) 0

Plant consumption 2 698 345 (100%) 2 698 345 (100%)
The diagrams below show the different results observed after installation of the dryer.
GE
CIE 1%
18%
TA
82%
TA CIE GE
After installing the dryer
CIE : 1.63%
TA : 98.37%
TA CIE GE
IV. Optimum choice of turbo-generators

In order to choose the most suitable turbo-generator for your needs, we will determine the
cycle efficiency for each turbo-generator.
The biomass power plant operates on the Rankine cycle:
Figure 15Rankine cycle
Given that we have back-pressure steam turbines and that the exhaust pressure is practically
identical for each turbine, the efficiency of this cycle is as follows:
Enthalpie de la vapeur surchauffée−Enthalpie de l' échappement

ηCycle = '
Enthapie de la vapeur surchaffée−Enthalpie de l eau d ' alimentation
Thus we have :
2942 , 05−2544 , 8
ηCycle = ∗100=15 , 87 %
2942 , 05−438 , 9
ηCycle =15 , 87 %
To be much more precise in our choice, we're also going to refer to the power of each turbo-
alternator.
Turbo generators Active power (kVA)

TA 1 998
TA 2 1875
TA 3 660
TA 4 710
Recommendations:
Thus we have :
 For heavier loads, such as plant start-up and tertiary housing and services, the TA 2 is
best suited to supporting all these loads.
 For heavy loads such as plant start-up only, TA 1 and TA 2 are best suited.
 For smaller loads, such as energy production for homes, TA 3 and TA 4 are best
suited.
V. Economic study of the project
1. Project investment cost

Our project is valued at 90 million CFA francs, broken down as follows:
Dryer investment cost 86 million FCFA
Dryer operating costs FCFA 4 million
Table 15Investment cost of the dryer
2. Savings achieved thanks to the project

The annual quantities saved are calculated on the diesel consumption of the generating set
during the campaign from January 2023 to June 2023, to which is added the reduction in CIE
consumption during the campaign based on our own estimates.
Knowing that the generator burns 0.33 litres to produce one kWh, we can estimate the diesel
consumption.
The selling price of a litre of diesel is 715 FCFA and the average price of electricity (kWh)
supplied by CIE is 73.49 FCFA (taking into account peak and off-peak hours).
The table below shows the various gains made with the installation of the dryer:

Diesel consumption during 5 868,06 0
the campaign (l)
Gains on diesel (FCFA) 4 195 663
CIE consumption during the 477 306 44 047,58

campaign (kWh)
Gains on CIE consumption 31 840 161
(FCFA)
Table 16Gains made by installing the dryer
The installation of the dryer will therefore enable us to make a saving of CFAF 36,035,824
over the period January 2023/June 2023. Given that the plant consumes much less energy
from the CIE and the generator during off-peak periods (July-December) than during peak
periods (January-June) because the loads are lower during this period, we can estimate that
the gain over this period is CFAF 15,000,000.
As a result, the gain for the year is estimated at FCFA 51,035,824.
3. Return on investment
The return on investment is :
'
cout d investissement
TRI =
économie mensuelle−cout de fonctionnement mensuel
90000000
AN : IRR = =1 , 76
51035824
IRR = 1.76, i.e. approximately 1 year and 277 days.
CONCLUSION
At the end of our work, having familiarised ourselves with the working environment while
studying the energy-producing installations, their context of use and their mode of operation,
we can say that we have complied with the specifications submitted to us. To do this, we
carried out an inventory of current performance by calculating boiler and cycle efficiency and
analysing the ratio kg vap /kg comb which are very important performance parameters. We then
compared the calculated values with those prescribed by the manufacturers. Using the
ISHIKAWA diagram, we were able to identify the various causes of excessive fuel
consumption by the boiler. These were, above all, the deterioration in fuel quality and
combustion, poor equipment settings, control equipment failures and information processing.
Finally, we made various recommendations and proposed solutions to resolve the problem.
We proposed improving combustion by installing a dryer, training staff in equipment settings
and compliance with instructions, and regular monitoring and appropriate maintenance of
energy production equipment. Implementing these solutions should generate annual savings
of 51,035,824 F CFA. This still requires an investment of 90,000,000 CFA francs, with a
payback period of 1 year and 277 days. We hope that this report will be of great benefit to
SIPEF-CI BOLO, and that beyond the maintenance work on the production tools, the real
problems will be solved to increase its performance and make its investments profitable.
BIBLIOGRAPHY
[1] : G MARTIN, " LE BILAN ENERGETIQUE DE LA CULTURE DU PALMIER A HUILE
", 290 pages
[2]: ALEXANDRE GRIZEAU, final year dissertation in Energy Design Engineering,

"OPTIMISATION DE LA CONCEPTION D'UNE CENTRALE DE COGENERATION
BIOMASSE PAR L'USAGE D'UN SIMULATEUR MIS AU POINT",
[3]: Dr OUATTARA ADAMA, Lecturer - researcher at the DFR GME of the INPHB,
"COURS CHAUDIERE", INPHB Yamoussoukro, 82 pages
[4]: Pr GHAHA, Teacher-researcher at the DFR GME of the INPHB, "COURS DE

BIOMASSE", INPHB Yamoussoukro, 39 pages
[5] : Dr OUATTARA ADAMA, Lecturer - researcher at the DFR GME of the INPHB, "
COURS TURBINES A VAPEUR ", INPHB Yamoussoukro, 25 pages
[6] : DANHO DJIRABOU, End of cycle dissertation in Energy Design Engineering, " BILAN
ENERGETIQUE ET AMELIORATION DES RENDEMENTS DES CHAUDIERES A
BAGASSE BR 2 43-68 DE SUCRIVOIRE BOROTOU-KORO ", INPHB Yamoussoukro, 115
pages
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option IX
WEBOGRAPHY
[7] : Site de la SIPEF-CI (page consultée le 10 Août 2023 à 08 H 55 min), [On line], URL :
https://sipefci.ci
[8] : ALAIN BRIAND, Mémoire de fin de cycle en Ingénierie de Conception en Energétique,

" APPORT ENERGETIQUE DU TOURTEAU DE PALMISTES ET POSSIBILITES
D'UTILISATION DE CE COMBUSTIBLE DANS LES CHAUDIERES A DECHETS DE
PALMCI (CASE DE L'HUILERIE D'IBOKE) ", (Accessed on 16 August 2023 at 16h45min),
[On line], URL : https://www.kupdf.net/download/pfe-briand-alainapport-energetique-du-
tourteau-de-palmiste_5af4fb69e2b6f54e31204df8_pdf
[9] : FAYE PAPA, Mémoire de fin de cycle, " ANALYSE ET OPTIMISATION DE LA

PRODUCTION D'ENERGIE RENOUVELABLE D'ORIGINE BIOMASSE ", (Consultée le 23
Août 2023 à 21h27min), [On line], URL :
http://documentation.2ie-edu.org/cdi2ie/opac_css/doc_num.php?explnum_id=1938
[10] : Séchoir Turbo dryer (page consulted on 15 September 2023 at 11 H 43 min), [On line],
URL : https://www.jls-europe.de/fr/products/dryer/standard-turbo-dryer.html
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option X
APPENDIX 1
Figure 16RESPO certificate
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XI
APPENDIX 2
Figure 17Sterilisation cycle
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XII
APPENDIX 3
Figure 18Technical characteristics of the BM boiler
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XIII
APPENDIX 4
 Turbo generator 1
Figure 19Technical characteristics of the TA 1 turbine
Figure 20Technical characteristics of the TA 1 alternator
 Turbo generator 2
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XIV
Figure 21Technical characteristics of the TA 2 turbine
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XV
APPENDIX 5
Figure 22Generator characteristics
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XVI
APPENDIX 6
Figure 23Composition of fresh diets
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XVII
APPENDIX 7
Manufacturing number 0617-033-0013
manufacturer Wyssmont
Model OE20
Capacity Electric
Dimensions L*W*H 4*1,5*2,5
Air flow rate 10000-15000 m /h3
Table 17Technical characteristics of the dryer
TABLE OF CONTENTS
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XVIII
DEDICATION.........................................................................................................................I
ACKNOWLEDGEMENTS....................................................................................................II
FOREWORD........................................................................................................................III
CONTENTS..........................................................................................................................IV
LIST OF FIGURES................................................................................................................V
LIST OF TABLES................................................................................................................VI
ACRONYMS AND ABBREVIATIONS............................................................................VII
SUMMARY.......................................................................................................................VIII
INTRODUCTION...................................................................................................................1
PART 1: PRESENTATION OF THE COMPANY AND THE THEME...............................2
I. Presentation of the company............................................................................................3
1. Background to the creation of SIPEF-CI.....................................................................3
2. History of SIPEF-CI.....................................................................................................3
3. SIPEF-CI......................................................................................................................4
II. Presentation of the end-of-study project..........................................................................8
1. Title of the theme.........................................................................................................8
2. Specifications...............................................................................................................8
PART 2: STUDY OF THE EXISTING SITUATION............................................................9
I. Crude palm oil production process and principle of biomass cogeneration..................10
1. Crude palm oil production process.............................................................................10
2. Principle of biomass cogeneration.............................................................................14
II. General description of the biomass plant and other energy sources..............................15
1. Description of the biomass power plant.....................................................................15
2. Boiler..........................................................................................................................15
3. The power plant..........................................................................................................20
III. Analysis of fuel used..................................................................................................22
1. Elemental mass composition of fuel components......................................................22
2. Fuel characteristics.....................................................................................................23
IV. Analysis of the quantity of fuel and steam consumed by the boiler..........................26
1. Calculating the ratio kgvap /kgcomb ..........................................................................26
2. Current fuel situation..................................................................................................26
V. Analysis of the specific consumption of turbo-alternators and breakdown of electrical
energy production and consumption.....................................................................................28
1. Specific consumption of turbo-alternators.................................................................28
2. Breakdown of electricity production and consumption.............................................28
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XIX
VI. Boiler energy balance.................................................................................................30

1. Method for calculating boiler performance indicators...............................................30
2. Results........................................................................................................................32
PART 3: OPTIMISING THE BIOMASS POWER PLANT................................................35
I. Optimum boiler operation..............................................................................................36
1. Ishikawa diagram.......................................................................................................36
2. Recommendations......................................................................................................39
II. Optimising combustion quality in the boiler and fuel storage.......................................40
1. Fuel quality.................................................................................................................40
2. Fuel drying.................................................................................................................41
3. Dryer sizing................................................................................................................42
4. Fuel storage................................................................................................................47
III. Optimising biomass energy production in relation to other energy sources..............47
IV. Optimum choice of turbo-alternators.........................................................................51
V. Economic study of the project.......................................................................................53
1. Project investment cost...............................................................................................53
2. Savings generated by the project................................................................................53
3. Time to return on investment.....................................................................................54
CONCLUSION.....................................................................................................................55
BIBLIOGRAPHY.................................................................................................................IX
WEBOGRAPHY....................................................................................................................X
APPENDIX 1........................................................................................................................XI
APPENDIX 2.......................................................................................................................XII
APPENDIX 3.....................................................................................................................XIII
APPENDIX 4.....................................................................................................................XIV
APPENDIX 5.....................................................................................................................XVI
APPENDIX 6....................................................................................................................XVII
APPENDIX 7..................................................................................................................XVIII
TABLE OF CONTENTS...................................................................................................XIX
KONAN Claude Esaïe, 3rd year STGI engineering student, PGE option XX

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OPTIMISATION OF THE BIOMASS POWER PLANT :

THE CASE OF THE BOLO OIL MILL

I dedicate this memoir :

 To the Lord JESUS for all he has done and continues to do in

 Dr Moussa DIABY, Director General of the Institut National Polytechnique Félix

1. Industrial Engineering Science and Technology (STGI) ;

PART 1: PRESENTATION OF THE FACILITY

PART 2: STUDY OF THE EXISTING SITUATION

I. Crude palm oil production process and the principle of biomass

PART 3: OPTIMISING THE PLANT

I. Optimum boiler operation

Figure 1: History of SIPEF-CI....................................................................................................3

Table 1: Characteristics and roles of conveyors.......................................................................16

ACRONYMS AND ABBREVIATIONS

PART 1: PRESENTATION OF THE COMPANY AND

1. Background to the creation of SIPEF-CI

Figure 1History of SIPEF-CI

3.1. Activities of SIPEF-CI

SIPEF-CI's main activities are :

 Supervision of village planters ;

3.2. Missions of SIPEF-CI

As part of its RESPO certification, SIPEF-CI undertakes to:

Appendix 1 shows the RESPO certificate.

3.3. E.A.I de BOLO

Figure 2BOLO site

Figure 3Location of SIPEF-CI BOLO

3.4. BOLO E.A.I. organisation chart

Figure 4BOLO E.A.I. organisation chart

II. Presentation of the end-of-study project

PART 2: STUDY OF THE EXISTING SITUATION

I. Crude palm oil production process and principle of biomass

1. Crude palm oil production process

NB: Palm kernels are used as fuel.

2. Principle of biomass cogeneration

2.1. Schematic diagram of biomass cogeneration .

Feed water Low-pressure storage Process

Figure 5Principle of biomass cogeneration

2.2. How it works

II. General description of the biomass plant and other energy

1. Description of the biomass power plant

Figure 6Operating diagram of the biomass power plant

Figure 7Boiler illustration diagram

Figure 8Schematic diagram of the BoilerMech boiler at the factory

2.2. Boiler components

Equipment Types Quantit Roles

Equipment Type Quantity Role

Carries heat, ash and debris

Equipment Types Quantity Roles

Table 3Characteristics and roles of locks

Equipment Types Quantity Roles

Table 4Characteristics and roles of air supply units

Equipment Types Quantity Roles

boiler with water from the

Equipment Quantity Role

 Raw water treatment

 Packaging in a food tarpaulin

2.3. How it works

3. The power station

3.1. Turbo generator

The technical characteristics of the various turbo-alternators are given in Appendix 4.

The diagrams below show the various turbo-alternators (TA):

Figure 9View of the TA