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EPF 4707

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Flow Diagram of

Palm OilMilling

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RESEARCH FOR THE REDUCTION OFMETHANE RELEASE FROM MALAYSIAN PALMOIL MILL LAGOON & ITS COUNTERMEASURES

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Palm Oil Industry In Malaysia

- 1st

Generation Palm Oil Mill -

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Palm Oil Industry In Malaysia

- 2

nd

Generation of Palm Oil Mill -

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Palm Oil Industry In Malaysia- Comparison 1st& 2nd-

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WHAT IS

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The Clean Development Mechanism(CDM) is anarrangement under the Kyoto Protocolallowingindustrialized countries with a greenhouse gasreductioncommitment (called Annex 1countries) to invest in

ventures that reduce emissions in developing countries as analternative to more expensive emission reductions in their

own countries.

A critical characteristic of an approved CDM carbonprojectis that it has established the planned reductionswould not occur without the additional incentive provided

by emission reductions credits.

Clean Development Mechanism (CDM)

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The CDM allows net global greenhouse gas emissions to be

reduced at a much lower global cost by financing emissions

reduction projects in developing countries where costs are

lower than in industrialized countries.

The CDM is supervised by the CDM Executive Board (CDM

EB) and is under the guidance of the Conference of the

Parties (COP/MOP) of the United Nations FrameworkConvention on Climate Change (UNFCCC).

Clean Development Mechanism (CDM)

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A Model Mill Case Study

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Comparison of Methane Emission BetweenReported Value & Measured One

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Methane Emission fromPalm Oil Industry in Malaysia

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Palm Oil Biomass Output fromFFB in Year 2006

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The two main wastes that are generated in a CPO mill are:Empty Fruit Bunches (EFB)Combined Liquid Palm Oil Mill Effluent (POME)

EFB:For every tonne of Fresh Fruit Bunch (FFB) processed,

there will be about 22% or 0.22 tonne of EFBs.

The conventional way to deal with EFB is toincinerate which contribute to high air pollution.

As this is prohibited in Malaysia and Indonesia now,

EFB are utilized for mulching.

Unfortunately mulching has some disadvantagesdue to high transportation and distribution costs,

long degradation time (up to one year), water

pollution by the rest oil and its attractiveness for

beetles and snakes.

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The two main wastes that are generated in a CPO mill are:Empty Fruit Bunches (EFB)Combined Liquid Palm Oil Mill Effluent (POME)

POMEFor every tonne of FFB processes there will beabout 0.65 tonnes of POME is produced. POME

consists of:

Sterilizer condensate (70%-75%)Clarification sludge (15%-20%)

Hydro cyclone discharge (5-10%)

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Mass Flow in Palm Oil Mill Process

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Oil Palm Waste Products

The oil palm mills generate many by-products and

wastes beside the liquid wastes that have been

mentioned, that may have a significant impact on theenvironment if they are not properly dealt with.

The most common among these by-products is the

empty fruit bunch.

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The empty bunch is a solid waste product ofthe oil palm milling process and has a high

moisture content of approximately 55-65%

and high silica content, from 25% of the total

palm fruit bunch.

The treated empty bunches are mechanically

crushed (de-watered and de-oiled) in theprocess, but are rich in major nutrients and

contained reasonable amounts of trace

elements.

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They have a value when returned to the field

to be applied as mulch for the enrichment of

soil.

However, it was noted that over application

of the effluent must be avoided as it may

result in anaerobic conditions in the soil byformation of an resistant coat of organic

matter on the soil surface

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Air emission from the oil palm mills are fromthe boilers and incinerators and are mainly

gases with particulates such as tar and soot

droplets of 20-100 microns and a dust load of

about 3000 to 4000 mg/nm.

Incomplete combustion of the boiler and

incinerator produce dark smoke resulting fromburning a mixture of solid waste fuels such as

shell, fiber and some times empty bunches.

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These boiler fly ashes are also a waste in themand also pose problems of disposal. In the bid to

achieve a zero discharge of the palm oil mill,

boiler fly ash have been used to reduce the BOD,TSS, colour and other contaminants from POME

before discharge.

Boiler fly ash has also been used in theremoval of heavy metals from other industrial

effluents

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Palm Oil Mill Effluent (POME)

Effluent water is defined as water dischargedfrom industry, which contains soluble materials

that are harmful to the environment.

Such soluble materials may be gases such as

CH4, S02, NH3, halogens or soluble liquids or

solids which contain ions of either organic or

inorganic origin and with their concentrationabove the entry value.

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Since these compounds are harmful to theenvironment, it becomes necessary that

effluents water should be treated or purified

before discharged into the environment.

Thus, the major objective of industrial

effluents treatment is to reduce the amount of

these potentially toxic compounds to theiracceptable threshold limit value (TLV), according

to some standards of the Federal Environmental

Protection Agency (FEPA); WHO; etc.

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Generally, the characteristics of industrial effluents aregiven as follows:

Soluble organics resulting in dissolved oxygen

depletion in streams and estuaries and/or causing taste

and odour.Organic suspended solids resulting in dissolved oxygen

depletion.

Inert suspended solids causing turbidity and resulting

in bottom sedimentsToxic substances and heavy metals.

Oil and floating materials.

Dissolved salts particularly phosphates, chlorides and

nitrates

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Specifically, palm oil mill effluent (POME), is a general

phrase referring to the effluent from the final stages of

palm oil production in the mill.

It includes various liquids, dirties, residual oil and

suspended solids.

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POME in its untreated form is a very high strength

waste, depending on the operation of the process, that is;

informal, semi-formal and formal processes, the

biological oxygen demand (BOD) of these wastes rangesfrom 25000 to 35000 mg/L.

It contains about 94% water. POME actually is the sum

total of liquid waste which cannot be easily orimmediately reprocessed for extraction of useful products

and is run down the mill internal drain system to the so

called effluent (or sludge) pit.

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POME is generated from various points during processingin an oil mill. These include:

Clarification sludge

Sterilization condensates

Fruit washing water

Hydro cyclone drain-off.

Various boiler blows down, tank and decanters

drain.

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The composition of the effluent from these various

sources, are mainly water, oil, solids (suspended and

dissolved) and sand. Adapalm effluent hand book, gave

the following composition as percentage of totalsludge;

Water : 93 95%

Solid : 34%

Oil : 0.5 2%

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Also, Sutanto, reported the following composition

from analysis of typical sample from Malaysia;

Water : 95%Oil (free) : 1.0%

Suspended solids : 2.0%

Dissolved solids : 2.0%

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Regulatory Standards forPalm Oil Mill Effluent

Specifically after being given one year to install

treatment facilities, palm oil mills were required to

reduce their waste water discharges, taking biologicaloxygen demand (BOD) concentration as the key parameter

from 25000 mg/L untreated effluent to 5000 mg/L and to

(100 mg/L by 1984 on wards)

Palm oil mills were given one year (1978) of paying a

low fee for the biological oxygen demand load exceeding

a standard of 5000 mg/L in recognition of the initial

difficulties the industry would face.

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Regulatory Standards forPalm Oil Mill Effluent

A more stringent biological oxygen demand standard

(100 mg/L in 1984 on word) and hence, higher effluent

charges were compulsory after that.

The results of policy implementation are very

encouraging.

The palm oil industry made steady progress towardsmeeting the target of 100mg/L biological oxygen

demand.

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Industrial Pollution ControlStandards for Palm Oil Mills

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Palm Oil Mill Effluent Management

Effluent management involves the typical handling of

liquid waste.

The mechanical technique often involves sedimentation,

filtration and decolorization of effluent.

Mechanical technique is normally at the first stage of

purification process to remove suspended solid particles.

This is called primary treatment.

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The commonly used devices include sieve, sedimentation

bed and filter.

Physico-chemical technique involves coagulation of finelydispersed and suspended solid particles, adsorption of

the dissolved impurities such as heavy metals,

selective crystallization, reverse osmosis and ion-exchange

processes.

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Reverse osmosis is most often used at the final stage of

effluent treatment.

Secondary treatment is biological process followingprimary treatment.

The forms of secondary biological process include

activated sludge, tricking filters, contact stabilization, etc.

There are widely known methods of effluent treatment in

palm oil mill industries.

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Palm Oil Mill Effluent Management1. Tank digestion and facultative ponds:

In this system, raw effluent after oil trapping is

pumped to a closed tank which has a retention time of

about twenty days.

The liquid is mixed by means of horizontal stirrers.

The methane gas (CH4) generated is flared off into the

atmosphere, but the flaring of the CH4 is unacceptable andcalls for improvement on this method.

Digested liquid is discharged into a holding pond before it

is disposed on land.

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Palm Oil Mill Effluent Management2. Tank digestion and mechanical aeration:

This group consists of cooling/acidification ponds, an

anaerobic digestion tank and an aeration pond.

Raw effluent after oil trapping is pumped to the

acidification pond through a cooling tower and retained for

one to two days.

It is then mixed with an equal volume of liquid from theanaerobic digester before it is fed back to the digester and

the achievement recorded indicates that the effluent water

has been treated.

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Palm Oil Mill Effluent Management2. Tank digestion and mechanical aeration:

The hydraulic retention time of the digester is about

twenty days.

The digested liquid is discharged to an aeration pond with

two floating aerators.

The liquid is aerated for twenty days before it is

discharged.

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Palm Oil Mill Effluent Management3. Decanter and facultative ponds:

In a few mills, decanters are used to separate the fruitsjuice after pressing into liquid and solid phase, the liquid

which is mainly oil is fed to the conventional clarification

process.

The water resulting from the clarification station is

recycled.

The solid is either disposed off on land or is dried in a

rotary drier to about 10% moisture and then used as fuel.

Thus, the effluent which consists of only the sterilizer

condensate and waste from the hydro cyclone is greatly

reduced in volume and is treated in a series of ponds.

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Palm Oil Mill Effluent Management4. Anaerobic and facultative ponds:

This system consists of a series of ponds connected in

series for different purposes.

The effluent after oil trapping is retained in an

acidification buffering pond for about two or three days,

the resulting effluent is then treated in an anaerobic pond

with a hydraulic retention time of thirty to eighty days

depending on the mills.

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Palm Oil Mill Effluent Management4. Anaerobic and facultative ponds:

This digested liquid is further treated in a series of

facultative ponds before it is discharged.

In some cases, part of the digested liquid is recycled tothe acidification and buffering pond.

The total hydraulic retention time of the system ranges

from 75 to 120 days.

l l ll ffl

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Palm Oil Mill Effluent Management5. Antra system:

The treatment consists of a combination of mechanical

chemical process and ponds.

The raw effluent after oil trapping is separated into water

and solid phases using a three- phase decanter.

The oil is returned to the main line while the solid isdried in a rotary drier after the filter press.

P l Oil ill ffl

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Palm Oil Mill Effluent Management5. Antra system:

The water containing dissolved and suspended solids is

treated with coagulants and flocculants to remove as

much solids as possible before it is fed to an anaerobicdigester which has a hydraulic retention time of about

ten days.

The digested liquid is further treated in an aerationtower and then oxidized.

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W t M t

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Waste Management

Empty fruit bunches (EFB)

is now increasingly used for

mulching oil palms

The fibre from the EFBafter separation can be

used for pulp and paper

and production of panel

products

W t M t

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Waste Management

Treated palm oil mill effluent (POME) contains high level of plant

nutrients that may totally replace inorganic fertilizers

Treated POME applied to land improves the soil and increases yield

W t M t

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Waste ManagementUNTREATED EMPTY FRUIT BUNCHES

W t M t

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Waste Management

UNTREATEDEMPTY FRUIT BUNCHES

W t M t

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Waste ManagementTREATED EMPTY FRUIT BUNCHES WITH MICROB

W t M g t

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Waste Management

TREATEDEMPTY FRUIT BUNCHES

WITH MICROB

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ANY QUESTIONS ?

Documents

EPF 4707 - POME [14.05.2013]