(12) MALAYSIAN PATENT (11) MY-172437-A

(21) Application No. : PI 2011005868 (56) Prior Art:

CN 101680189 A
(22) Filing Date : 02 December 2011 CA 2091139 A1
PI 20084798
(47) Date of Publication and Grant: US 7736463 B1
25 November 2019 CN 101503867A1

(30) Priority Data : (72) Inventors :

2011101764045.0; 29/6/2011; CN Bian Jing

(51) Classification, INT CL : (73) Patent Owner :

D21B 1/00 Green Patent Technologies Sdn. Bhd.
5f-20, Pusat Perdagangan loi,
(74) Agent: No. 1, Persiaran Puchong Jaya Selatan,
Ramakrishna A/L Damodharan Bandar Puchong Jaya, 47100 Puchong,
Kass International Sdn Bhd Selangor
Malaysia

Oil Palm Waste Using Method Of Rbmp Low Carbon Recycling, Continuous Mechanical
(54) Title
Pulp Bleaching System

(57) Abstract :

This invention relates to an oil palm empty fruit bunches (EFB) and fronds as new raw
materials for using method of RBMP low carbon recycling, continuous mechanical pulp
bleaching system. It includes the following process flow: 1. Dry cleaning, extrusion separation,
dry method to separate the residue and impurities of EFB, screened dry waste to make into
biomass solid fuel; extruded and separated residual oil become coal agent through a one-step
pyrolysis process; 2. Counter-current displacement impregnation is transporting the fibers into
a immerse tank, stirring to achieve separation of the two solid-liquid displacement. The filtered
out gel-like lignin debris can be added into the solid bio-fuel and cleaned residue can be reused
in subsequent process. 3. The pre-steaming roller to soften, twist-grind continuous bleaching
is to transfer the impregnated fibers into steam pipe for softening and extrusion tearing; then
by impregnated devices send into the S-shaped spiral reactor in which fibers produce chemical
reaction during the operation, and 2-3% of sodium perborate is added in order to facilitate the
high-density refining for continuous bleaching. Then by the eliminator, hierarchical screening
process; finally a multi-functional high efficient refiner is used to make into pulp.

Figure 2
 1

OIL PALM WASTE USING METHOD OF RBMP LOW CARBON RECYCLING,

CONTINUOUS MECHANICAL PULP BLEACHING SYSTEM

FIELD OF INVENTION
5
The present invention relates to a new method of pulp making, especially on oil
palm empty fruit bunches (EFB) and fronds as raw materials. Using RBMP low carbon
recycling, continuous mechanical pulp bleaching system.

10 BACKGROUND OF INVENTION

Oil palm EFB is a waste after oil extraction, is considered as the "second timber" with thin
and long fiber, better than straw pulp and equivalent with hardwood pulp. It is a good
papermaking raw materials other than wood, suitable for high-grade paper production. Oil
15 palm is fast growing, short cycle, renewable. Once planted, benefits every year,
sustainable use and is the best alternative and complementary for wood pulp.

Generally speaking, the use of oil palm pulp has the following advantages: First is a rich
resource where Malaysia is the world's most resource-rich country on oil palm species,
20 hectarage, and the annual output ranks first in the world. EFB waste alone abandoned 30
million tons each year. Indonesia, Thailand and Philippines and other countries every
year have 50 million tons of such waste, a lot of it goes to incineration and landfill with
large amounts of carbon dioxide emissions.

25 Using the above-mentioned method can produce paper pulp by means of "waste
recycling", protecting our country as the world's forest resources, ease the
implementation of national natural forest protection project, make our country originally
belongs to the small forest country, per capita forest area is small, and the rapid
development of economic causing imbalance of the timber supply and demand which
30 leads to more critical situation. Pulp making using this method, can substitute wood of 25
million cubic meters each year (based on ratio of 4:1 in pulp making), reducing 1 million
hectares of forest harvesting area, producing oxygen of 1.6 billion tons,■ reducing the
burning of EFB which polluting the atmosphere, and using EFB to produce paper can
transfer the compiled EFB carbon into the paper.
35
Oil palm EFB, with moisture of 56%, residual oil of 2.8%, lignin content of 17.7%, palm
cellulose content of 86.3%, small fiber content of 27.2%, hot water extract of

2 DEC 2011
 2

9.3%, 1% alkali extract of 29.6%. As of to date, there is no relevant patents and papers
on how the low-carbon and efficient use of the combined cycle of such raw materials in
accordance with its materials characteristics.

5 The new search on the existing chemical methods, because of its high chemical
consumption, higher production costs, large investment, and wastewater treatment is not
easy, the stiffness of the corrugated paper produced is poor; the method is not desirable.

Semi-chemical, due to uneven processing of raw materials, so the pulp formed is uneven;
10 some of the chemical treatment of raw materials is too heavy, some material was still raw,
succeed to become paper strength is low.

The present invention provides a new concept, especially the use of EFB of its own
characteristics. The use of RBMP is to recycle the raw material, continuous pulp
15 bleaching method. The method is with low energy consumption, low production
costs, high gaining rate of pulp, high production efficiency, high brightness, especially
fully utilized the waste of waste with RBMP method to achieve low-carbon EFB pulp
making.

20

2 DEC 2011
 3

SUMMARY OF INVENTION

The purpose of the present invention is to provide a method of using oil

palm EFB, trunk, lower frond as raw material with the use of EFB its own characteristics,
5 fully utilized the raw materials during the feed preparation and pulping process with
the RBMP method of pulping. It rarely discharges the black liquor, and the process is
simple, easy to operate.

To achieve the above objectives, the technical solutions adopted in this present
10 invention are:

I. Dry Cleaning To Remove Impurities, Extrusion Separation and Residue

Utilisation

15 A. Screen Beat: Oil palm EFB feed preparation is essential, oil palm EFB itself is a
mixture of fruit shell, fruit skin break residue, sandy mud, and other light and
heavy impruties such as shoot stem, etc. Firstly, use the patented design of the
EFB Round Hit Screen with the dry method to separate EFB impurities for having
a clean EFB. The screened dry waste can be made into biomass solid fuel.
20
B. Tearing Extrusion: Using the current inventor’s Tearing Extrusion Separator to
tear and extrude the cleaned EFB, isolate 20 - 25% of moisture and 1.8% of
residual oil from raw materials, the isolated EFB fibers go to the next process,
residue to Oil-Water Separator for isolating out the residual oil, through one-step
25 pyrolysis process become biomass fuel oil, added to the biomass solid fuel to
increase its combustion value.

C. Fiber Shattering: After tearing and extrusion of the EFB fibers, the fibers still
require to be shattered with Fiber Shattering machine in order to achieve the pulp
30 making requirements in which the raw materials become 20 - 40mm long single
palm fiber.

D. Impregnated Mixing: The stirred well palm fibers are sent to the next process by
screw conveyor. During the transmission, added with the white pulp residues fluid
35 of 5 - 7%; biochemical catalyst solution agent of 12 - 14%, and to reduce the
surface gas absorption of palm fibers.

2 DEC 2011
 4

II. Counter-current Displacement Impregnation

A. Impregnation Conditions; The impregnated palm fibers transported to the immerse

5 tank, the ratio of raw material and impregnated liquid is 1; 5 -1:8; according to the
Malaysian local climatic conditions whole year at 28-33°C, external impregnated
silo to be coated with heat-absorbing material, impregnation can be achieved
without additional steam for the conditions of 28-58°C, the silo can be vertical
mixing, stirring to eliminate bubbles, full immersion of 6 - 7 hours, when the palm
10 fibers hardness (potassium permanganate value) reached 13 - 14, the adsorption
separation of impregnating solution to reuse in the next impregnation process.
After drain off can go to the next process. (The impregnated silo is the
displacement of closed loop flow recycling)

15 B. Replacement of Solid-Liquid Separation: First extraction of liquid waste, the

concentration is about 32%, then add back with recycle water for adsorption,
extraction recovery of 60-70% residue. Residue using 15-20 micron filter, to
achieve separation of the two solid-liquid displacement, the filtered out gel-like
lignin debris can be added into the bio-solid fuel, cleaned residue to reuse in
20 subsequent process.

III. The Pre-steaming Roller to Soften, Twist Grind Continuous Bleaching

A. Pre-steaming: The well impregnated palm fibers after measuring tools to transfer
25 into the steam pipe, and add with 2% NaOH, 1.8% of HOH2 and 0.05% of DTPA, a
model ZYM 2 - 4% pulp penetrant at temperature of 80-90°C at pre­
steaming time of 25-35min, steam pipe is of screw mixing conveyor.

B. Using Twin-Screw Pulp Twisting Machine to carry on the extrusion, tearing and
30 bleaching on the steamed soften raw materials. The Twin-Screw Pulp Twisting
Machine is divided into four high-pressure zone. The first and second zone is to
squeeze out a small amount of white fluid from the soften raw materials. The third
zone added with 2-3% of sodium hydroxide, 0.05-0.1% of magnesium sulfate, 2­
3% of sodium silicate mixture. The fourth zone added with hydrogen peroxide
35 enzyme. In this section, the thick white liquid was concentrated and adding into

2 DEC 2011
 5

the biomass fuel, the grinded coarse pulp through the impregnated device will
transfer into the S Screw Reactor.

C. In the S-type Spiral Agitator Reactor, react during the operation and added with 2­
5 3% of sodium perborate, in order to facilitate the High-Density Refining for
continuous bleaching, reaction time of 45-60min, temperature of 70-80°C, bulk

density of 170-200kg / m3, the brightness of the reactor can be up to 65-75%.

D. High-Density Refining & Refiner Bleaching: According to the physical properties of

10 oil palm fibers, using high-density refining with refining concentration of 25-30%
will not damage the fibers. Using unreacted chemicals from the Reactors to further
continuous bleaching in a short time through high temperature and performance of
mixed plate refiner, the pulp brightness can achieved up to 80%.

15 IV. The Eliminator, Hierarchical Screening Process, pulp fibers after the high-density
refining had distortions, eliminating in pulp tank at 40-60 °C for 3 - 4 hours, re-use
hole or slit sieve, in the density of 0.5 - 2.5%, the good pulp screen into the next
process, screening of the crude residue then back to the refining process will not
be repeated the next qualified pulp wear.
20
V. Pulp formed, the use of multi-functional and high efficient refiner, rotor, stator for
the three-dimensional three-level model, large refining area, low power
consumption, fiber separation with significant effects, forming of pulp with pulp
beating rate of up to 26-30°SR .
25
The chemicals of the above catalyst solution agent are:
Cellulase : 0.2-0.3%;
Laccase : 0.3-0.5%;
Magnesium Hydroxide : 0.1-5%.
30
Chemicals used in cellulose, can change the fiber surface and the residual oil connection
key, for which is the separation of residual oil in the EFB fibers by washing or flotation
removal after soaking.

2 DEC 2011
 6

Laccase is an extracellular copper oxidase, have the ability of catalytic oxidation of lignin;
can catalyze the phenolic groups of lignin occurs in single-electron oxidation to generate
oxygen free radicals, the occurrence of non-enzymatic reaction.

5 Magnesium Hydroxide can degrade fibers, the pulp, iron, manganese ion content. At the
same time have amortize function, pH value is easy to control, pulp brightness can be
maintained, improved pulp viscosity, reduce COD content and production costs, cab be
used as wetting agent when soaking fibers, softening EFB fiber.

10 Soaking catalyst as prepared and described, first by adding magnesium hydroxide to the
wet water and stir evenly in water at 600, in proportion added in the other two enzymes
agent, basically stirring in 30-40min, can be made of non-toxic, odorless, environmentally
friendly immersion.

15 Countercurrent Displacement Impregnation as described, mainly impregnating the palm

fibers into four immerse tanks. Four impregnating solution tanks using countercurrent
displacement impregnation, fresh catalyst solution liquid supplement in the third tank, the
first tank set filter compartment, recycling of the catalyst solution liquid. The solid
materials excluded by filtration to do biomass fuel material, the residue go to the fourth
20 tank to continue recycling. The catalyst solution liquid of this section is 3-5 times of the
solid materials, temperature of 60-75 °C, impregnation time of 60-90min, each liquid off at
dryness of 25-35%.

The type of pulp penetrant zym as described, is a new energy-saving additives, can
25 significantly shorten the pre-steaming time, reduce the amount of NaOH, slow dissolution
rate of fibers, reduce fiber degradation, effectively improve the pulp yield, increase the
average fiber length, improve the folding resistance of paper, tear-resistant, tear-off
degree, bursting strength, and other physical indicators, so that the pulp making is more
environmentally friendly.
30
The advantages of the present invention: -

First: use of oil palm renewable resources of EFB, achieving the recycling during the pulp
making, no discharge of liquid or solid waste to achieve low-carbon pulp. Firstly, use oil
35 palm EFB method of dry cleaning to remove impurities, extrusion separation, and residue
utilization. EFB itself impurities, more oil waste which containing residual oil and fruit
shell, fruit skin flap residue, sandy mud, hard black stems. Existing methods is directly

2 DEC 2011
 8

time 60min. The mixing strength of the refiner, high temperature to increase the bleaching
in a short time, to ensure the uniformity of the bleaching chemicals suspension in the
pulp; adding sodium perborate in the second stage increased brightness up
to 20 percent, other strength properties are also improved, and to prevent the refiner from
5 plate mill scale.

2 DEC 2011
 9

Illustrations shows: -

Figure 1 : Flow Chart on the Counter-current Impregnation Recycle Tank of the

Present Invention
5 Figure 2 : Flow Chart on the Low Carbon Pulp Recycling With the Use of
Renewable Resources of the Present Invention.

2 DEC 2011
 11

add with 3-4% hydrogen peroxide enzyme. The white liquor residual squeezed out
from this section go to immerse tank, the coarse pulp will transfer into reactor.

7. In the S-type spiral reactor operation by adding 2-3% sodium perborate, in order to
5 prevent a high density refining from creating dirt, temperature at 70-90°C, bulk
density 170-200kg/M3. After 45-60min of reaction, re-use of high density refining and
high temperature, high-mixed performance disk refining bleaching refining, refining
density of 25-30 percent.

10 8. The good bleach refined pulp eliminating in pulp tank at 40-60 °C for 3-4 hours. After
screening and enter the multi-functional and high-efficient refiner, rotor, stator for the
three-dimensional three-level model, go to low density pulping, immediately forming of
pulp with pulp beating rate of up to 26-30 ° SR. Brightness of 80% ISO, 86% pulp
yield. If the chemi-mechainsed original pulp goes to papermaking of 70g/m 2 light
15 grammage paper, tensile index is 48NM/g, tearing index a 4.9MN.m 2/g, fiber breaking
length of 4.8km.

Example 2

20 The present invention of clean high yield process prepare for oil palm fronds

1. The oil palm fronds, through extrusion machine tearing and crushing, skin rod
screening separation, rods for the pulp making, skin after the separation can be made
into biomass fuel.
25
2. After tearing the palm fibers and the screw conveyor, send into the countercurrent
displacement impregnation tank. During the transmission, added with white pulp
residual fluid of 5-7%, 12-14% biochemical catalyst solution agent.

30 3. The ratio of palm fiber with impregnated liquid is 1:5 -1:8, soaking temperature of 35 -
60°C, soaking time of 6 - 7 hours, biochemical agents in the impregnated catalyst
solution in the storage group using counter-current replacement cycle, the first
immerse tank consists of 15-20 micron filter, to achieve solid-liquid separation. The
filtered out gel-like lignin debris can be added into biomass fuel
35

2 DEC 2011
 12

4. The wells impregnated and soften fronds fibers go into pre-steaming roller. Only for
20-30min can achieved the steam requirements. At this section, adding with 1.8%
NoH 2, 0.05% DTPA, 2-4% pulp penetrant at temperature of 80-90°C.
5. Using twin-screw pulp twisting machine on the pre-steamed fiber to carry on extrusion
5 and tearing become floss-like shape, according to sequence by adding 2-4% sodium
oxide, 0.5-0.1% magnesium sulfate, 3-4% of sodium silicate mixture and 3­
4% hydrogen peroxide enzyme. The white liquor residual squeezed out from this
section go to immerse tank for reuse, the coarse pulp will transfer into reactor for
reaction.
10
6. During the transfer movement in the S-type spiral agitator reactor, by adding 2­
3% sodium perborate, temperature 70-90°C, bulk density 170-200kg/M 3.
After 60min of reaction, reuse of high density refining, high temperature, high-mixed
performance disk refining bleaching, refining density of 25-30 percent.
15
7. The good bleached pulp eliminating in pulp tank at 40-60 °C for 3-4 hours. After
screening and enter the multi-functional and high-efficient refiner, rotor, stator for the
three-dimensional three-level model, go to low density pulping, one time pulping with
pulp beating rate of up to 26-30°SR, 85% pulp yield and brightness of 80% ISO.
20
From Example 1 and Example 2 shows, the bleached mechanical pulp produced by
present invention has superior performance, is able to produce newsprint paper, · made
lightweight copy paper, double-sided adhesive paper, etc. And energy saving than the
traditional pulping process, low carbon environmental protection, so that make use of all
25 renewable resources, greatly reducing the cost of pulp.

2 DEC 2011
 13

CLAIMS

1. A method for producing paper pulp from fibrous oil palm waste, comprising the
following steps:
5 i) cleaning, extruding and shattering the fibrous oil palm waste to produce fibers;
ii) transmitting said fibers obtained from step i) to an immerse tank and impregnating
with 5% to 7% of white pulp residues fluid and 12% to 14% by weight of a
biochemical catalyst solution agent while transmission;
iii) immersing the impregnated fibers obtained in step ii) in the immerse tank for 6 - 7
10 hours;
iv) transferring the impregnated fibers obtained from step iii) into a steam pipe and
adding 2% of sodium hydroxide, NaOH; 1.8% of holmium hydride, H0H2 and
0.05% of diethylene triamine pentaacetic acid, DTPA and 2 - 4% by weight of
pulp penetrant to the impregnated fibers at a pre-steaming temperature of 80 -
15 90°C for a time duration between 25 minutes to 35 minutes to obtain steamed
softened fibers;
v) extruding, tearing and bleaching said softened fibers obtained from step iv) to
obtain grinded coarse pulp;
vi) continuously bleaching the coarse pulp obtained from step v) by adding 2% to 3%
20 by weight sodium perborate to the course pulp at a temperature between 70°C to
80°C;
vii) performing high density refining to obtain pulp fibers having brightness of 80%
ISO;
viii) eliminating pulp fibers obtained from step vii) in a pulp tank at a temperature
25 between 40°C to 60°C for a duration of 3 hours to 4 hours; and
ix) screening the pulp fibers obtained from step viii) for forming the paper pulp.

2. The method as claimed in claim 1, wherein the fibrous oil palm waste is selected from
30 the group consisting of Empty Fruit Bunches (EFB), trunk and lower frond.

3. The method as claimed in claim 1, wherein the step of cleaning, extruding and
shattering fibrous oil palm waste includes:
i) separating impurities from the fibrous oil palm waste using a dry screening
35 technique to obtain a clean fibrous oil palm waste;
ii) tearing and extruding the cleaned fibrous oil palm waste obtained from step i) to
obtain fibers; and --.—

PI 2011005868
 14

iii) shattering the fibers obtained from step ii) to obtain fibers having a length between
20mm to 40mm.

4. The method as claimed in claim 3, wherein the screened dry wastes obtained from
5 step i) are converted into biomass solid fuel.

5. The method as claimed in claim 3, wherein the step of tearing and extruding the
cleaned fibers includes isolating 20% to 25% of moisture and 1.8% of residual oil from
the cleaned fibers.
10
6. The method as claimed in claim 3, wherein residue obtained from the step of tearing
and extruding the cleaned fibers is sent to an oil-water separator for obtaining residual
oil.

15 7. The method as claimed in claim 3, wherein residual oil obtained from the step of
tearing and extruding the cleaned fibers will go through one-step pyrolysis process
become biomass fuel oil and is added into biomass solid fuel.

8. The method as claimed in claim 1, wherein the biochemical catalyst includes 0.2 -
20 0.3% by weight of cellulose, 0.3 - 0.5% by weight of laccase and 0.1 - 5% by weight of
magnesium hydroxide.

9. The method as claimed in claim 1, wherein said immerse tank is coated with heat­
absorbing material on its exterior surface.
25
10. The method as claimed in claim 1, wherein said fibers obtained from step iii) and
impregnation liquid are immersed in the immerse tank in the ratio between 1:5 to 1:8.

11. The method as claimed in claim 1, wherein said fibers in step iii) are immersed until
30 the fibers reach a hardness (potassium permanganate value) of ranging in between
13-14.

12. The method as claimed in claim 1 and 11, wherein said fibers in step iii) are immersed
until the fibers reach a hardness (potassium permanganate value) of 13.4.
35
13. The method as claimed in claim 1, 4, 6 and 7, wherein the pre-steaming temperature
in the steam pipe is generated using the biomass solid fuel, wherein the residual oil is
added to the biomass solid fuel for generating steam / power.

PI 2011005868
 15

14. The method as claimed in claim 1, wherein the step of extruding, tearing and
bleaching said softened fiber includes using a pulp twisting machine which comprises
four high-pressure zones, wherein a white fluid is squeezed from the softened fiber in
the first and second zone of the machine, the softened fiber is then subjected to the
5 third and fourth zone, wherein the third zone contains 2 - 3% by weight of sodium
hydroxide, 0.05 - 0.1% by weight of magnesium sulfate and 2 - 3% by weight of
sodium silicate mixture and the fourth zone contains hydrogen peroxide enzyme.

15. The method as claimed in claim 1 and 14, wherein the bleached coarse pulp are
10 subjected to further bleaching the coarse pulp until a brightness of 65% to 75% ISO
is obtained with a bulk density of 170 - 200Kg/m3.

16. Paper pulp prepared in accordance with the method as claimed in claim 1.

15 17. The paper pulp as claimed in claim 16, wherein the paper pulp is characterized by
pulp beating rate of 26 to 30°SR and brightness of 80% ISO.

PI 2011005868
 16

ABSTRACT

OIL PALM WASTE USING METHOD OF RBMP LOW CARBON RECYCLING,

CONTINUOUS MECHANICAL PULP BLEACHING SYSTEM
5
This invention relates to an oil palm empty fruit bunches (EFB) and fronds as new raw
materials for using method of RBMP low carbon recycling, continuous mechanical pulp
bleaching system. It includes the following process flow: 1. Dry cleaning, extrusion
separation, dry method to separate the residue and impurities of EFB, screened dry
10 waste to make into biomass solid fuel; extruded and separated residual oil become coal
agent through a one-step pyrolysis process; 2. Counter-current displacement
impregnation is transporting the fibers into a immerse tank, stirring to achieve separation
of the two solid-liquid displacement. The filtered out gel-like lignin debris can be added
into the solid bio-fuel and cleaned residue can be reused in subsequent process. 3. The
15 pre-steaming roller to soften, twist-grind continuous bleaching is to transfer the
impregnated fibers into steam pipe for softening and extrusion tearing; then by
impregnated devices send into the S-shaped spiral reactor in which fibers produce
chemical reaction during the operation, and 2-3% of sodium perborate is added in order
to facilitate the high-density refining for continuous bleaching. Then by the eliminator,
20 hierarchical screening process; finally a multi-functional high efficient refiner is used to
make into pulp.

Figure 2
 1/2

Liquid Catalyst Solution

Incoming materials Raw materials

Liquid waste pump

Figure 1

2 DEC 2011
 2/2

Low Carbon Green Pulping Process

Empty Fruit Bunches

1
Dry Cleaning: Round Hit Screen -»White -»Biomass Solid Fuel-* BoBer — Steam (or Power)

Tearing Extrusion -* Oil-WMer Separetion -* Residual OB -+ Catalytic Pyrolysis -4iesly Oil

I
Fbsr Shattering —* Residue----------------------------------------------------------------------------------------------------

Countercurrent Displacement Impregnafion -* Water impurity Separetion -+ Impurities-------------

Add Chemical -* Pre-steaming RoBerCatelyfic Tank «-----------1----------------------------------------

I Oar Liquid
Add Chemical -»Adp Twisting Extrusion -+ Concentrated Black Liquor------------------------------------------

I
\ΛΙΟ»ΐηΜ·Ι HIwIv^RIWII JXVwvMVIl

I “
Plate Refiner Bleaching

I
Eliminator

I
Screening -+ Coarse Pulp —

I
Pulp Forming

I
Paper Making

Figure 2

2 DEC 2011