palm complex model
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11
Wahono SumaryonoDeputy Chairman for Agroindustry and BiotechnologyAgency for the Assessment and Application of Technology
(BPPT)INDONESIA
4th Biomass-Asia WorkshopKuala Lumpur-Malaysia, 20-22 November 2007
An integrated preliminary concept for sustainable plantationand CPO-based industries
E-mail address : wahono@ceo.bppt.go.id
22
YearYear AreaArea(Ha)(Ha)
ProductionProduction(Tonnes)(Tonnes)
19951995
2,024,92,024,986 86
4,479,670 4,479,670
19961996
2,249,52,249,514 14
4,898,658 4,898,658
19971997
2,922,22,922,296 96
5,448,508 5,448,508
19981998
3,560,13,560,196 96
5,930,415 5,930,415
19991999
3,901,83,901,802 02
6,455,590 6,455,590
20002000
4,158,04,158,077 77
7,000,508 7,000,508
20012001
4,713,44,713,435 35
8,396,472 8,396,472
20022002
5,067,05,067,058 58
9,622,345 9,622,345
20032003
5,283,55,283,557 57
10,440,834 10,440,834
20042004
5,447,55,447,562 62
11,810,00011,810,000
20052005
5,597,15,597,15858
14,520,00014,520,000
20062006 6,075,0006,075,000 16,000,00016,000,000
0
4
8
12
16
95 96 97 98 99 '00 '01 '02 *03 *04 *05 *06
Year
Million
Area (Ha) CPO Production (Tonnes)
Soruce : Dept. of Agriculture, Statistic of Oil Palm Plantation and CPO Production, 2006
AREA & PRODUCTION INDONESIAN OIL PALM PLANTATION
33
0500.000
1.000.0001.500.0002.000.0002.500.0003.000.0003.500.0004.000.0004.500.0005.000.0005.500.0006.000.0006.500.000
1980 1985 1990 1995 2000 2005 2006
Year
Are
a (H
a)
Smallholder Total
AREA BY CATEGORY OF PRODUCER, COMPARISON GRAPH
Soruce : Dept. of Agriculture, Statistic of Oil Palm Plantation and CPO Production, 2006
44
AREA & PRODUCTION INDONESIAN OIL PALM PLANTATION
Source : Dept. of Agriculture, 2006
55
COMPOSITION OF PALM PLANTATION COMPOSITION OF PALM PLANTATION AND OIL PALM PRODUCTAND OIL PALM PRODUCT
Plantation,6 Million ha
Male Flower 1,4,2 Million Tonnes
Roots 2,2,4 Million Tonnes
Shafts 2,13 Million Tonnes
Leafes 1,23 Million Tonnes
Fresh Fruit Bunches 1,3, 105 Million Tonnes
Shell, 7 Million Tonnes
Fiber,12,6 Million Tonnes
Palm Kernel Cake,4,4 Million Tonnes
PKO,2,9 Million Tonnes
CPO,23 Million Tonnes
Liquid Waste, 90 Million m3
BOD 20.000-60.000 ppm
Empty Fruit Bunches, 26 Million TonnesIndonesian plantation at 2006, assumed production at the
optimal age of palm oil trees beetwen 6-18 years, density 122 tree/ha (product/year at 2011)
1 daily product2 ready at replanting3 productivity of the productive palm oil trees 3,5 million tonnes/ha/year, 20% CPO
Biogas, 1.800 Million m3 ~ 3.300.000 MWh ~ 400 MW
Sludge
66
FLOW DIAGRAM OF CPO PRODUCTION
Flow Diagram of Palm OilConventional Processing
FFB Transportation
Loading Ramp
ThreserSterilization
Extraction
UNIT PURIFIKASI
Kernel Station
CPO
Kernel
Steam Generation
Steam Turbine
Fiber
Shell
Steam for Process
PKS
PKS MEDIUM
7
CPO DERIVATES
produced in Indonesian not yet produced in Indonesian Prepared in Indonesia
Oil Palm
Crude Palm Oil Palm Kernel Oil
OleinAmino Acid
PFAD Vit. A,E ß CarotenFatty Acid
StearinTriglyceride, Diglyceride,
Mono GlycerideIce
CreamLipase
Soap Chip
SCP
GlycerineCooking
OilSalad
OilShortening
Methyl Ester
Washing Soap
Methyl Ester
Fat Powder
Cocoa Butter
Substitute(CBS)
Margarine Cosmetics Shortenig Soaps VanaspatiVegetable
GeeCocoa Butter
Substitute(CBS)
Biodiesel
SurfactantPolymer
Confectioneries
Fatty Acid Ester
Palmitic/Propanol
Methyl Ester Sulfonate
Oleat/Glycol Propylene Glycol
Metalic Salt
Oleat Ba
Palmitic, Stearic/Ca, Zn
Stearic/Ca, M
Stearic/Al, Li
Oleic/Zn, Pb
Polyethoxylated Derrivatives
Palmitic/ Ethylene Propylene Oxide
Fatty Anines
Stearic/ Ethylene Propylene Oxide
Oleic Acid Dimer Ethylene
Propylene Oxide
Secondary C 16 & C 18 / Ethoxylated
Betain
C 16 & C 18 /Ethoxylated
Oxygenated Fatty Acid/Ester
Epoxy Stearic/Octanol Ester
Epthio Stearine Mono &
Polyhydric Alcohol Ester
Fatty Alcohol
C 16 & C 18 Alcohol/ Sulphate
C 16 & C 18 Alcohol / Esterified with Higher Saturated Fatty Acid
C 16 & C 18 Alcohol/ Ethoxylation
Monoglyceride Ethoxylation
Fatty Acid Amides
Stearamide
Alkanolamides
Sulphates Alkanolamides of Palmitic, Stearic &
Oleic Acids
Oleamide
Glycerol Food Emulsifier
88
INTEGRATED BIODIESEL PLANTINTEGRATED BIODIESEL PLANT
PALM OIL MILL BIODIESEL PLANT
BIOMASS POWER PLANT
FFB OIL
GLYCERINEPURIFICATION
BIOGAS PLANT
METHANOL PLANT
BIOMASSGASIFICATION
FURTHER APPRPROCESS
CATALYST RECOVERY
BIOMASS
BIODIESELPLANTATION
99
PROCESS FLOW DIAGRAMPROCESS FLOW DIAGRAMin General, for Small Plantin General, for Small Plant
Oil Storage
MethanolStorage
Biodiesel Storage
Glycerol Storage
Degumming TankNaOH
Drying
Washing
Filter
Distillation
GlycerolPurificatio
n
Reactor
Settling
FFA
Water
BIODIESELSNI 04-7182-
2006
Derivative ProductDevelopment
1010
1,3-PROPANEDIOL FROM GLYCEROL1,3-PROPANEDIOL FROM GLYCEROL
1,3-Propanediol
Bacteria
Glycerol 10%(byproduct)
Chemical feedstock
Biodiesel 90%
RME-Production(Refined Methyl Ester Production)
1111
Exterior coatings
CoatingsConstruction
resins
Waterborne polyurethanedispersions (PUD)
Environmental friendlyunsaturated polyesters (UP)
NEW COATINGS MADE OF 1,3-PDO, 3-HPA AND PALM OIL DERIVATES
1,3-PDO 3-HPAPalm oil derivates
Others
Interior coatings
1212
R&D ON BIOCHEMICALS AND BIOMATERIAL R&D ON BIOCHEMICALS AND BIOMATERIAL PRODUCTION FROM PALM OIL WASTE AND PRODUCTION FROM PALM OIL WASTE AND BIODIESEL BYPRODUCTBIODIESEL BYPRODUCT
1. Bioconversion of Oil palm Empty Fruit Bunch Fiber (OPFBF) into xylose and leading to biomaterials (PLA).
2. Physico~,chemical~, and then bioconversion of EFB into C6+C5 and leading to ethanol (2nd generation technology for ethanol production)
3. Microbial bioconversion of Palm Oil Mill Effluent (POME) into organic acids leading to biomaterials (PLA and PHB).
4. Microbial transformation of glycerol into 1,3-propanediol (PD) and 3-hydroxy propionic acid (HPA).
5. Development of bioproducts (coating, thermoplastics) based on 1,3-propanediol and 3-hydroxypropionic acid.
1313
PROCESS AND PLANT DEVELOPMENT CONDUCTED BY BPPT
1. SLS (Sodium Lauryl Sulphate)
2. MES (Methyl Ester Sulfonate)
3. GMS (Glycerol Mono Stearate)
4. SMS (Sorbitan Mono Stearate)
5. IPP and IPM (Isopropyl Palmitate/Myristate)
1414ISOPROPYL MYRISTATE (IPM) / ISOPROPYL PALMITATE
(IPP) PILOT PLANT, Capacity 15 kg/hourAgroindustry Technology Laboratory, PUSPIPTEK,
Serpong
IPP/IPM MILL, 15 TONNES/DAY Fix Investment Rp. 32 Bio (~USD 3.4 Mio) Working Capital Rp. 17,75 Bio (~USD 2.0 Mio)
UraianUraian ValueValue UnitUnit
NPV DF 20 %NPV DF 20 % 8.074.169.375 8.074.169.375 Rp Rp
IRRIRR 2929 % %
B/CB/C 1,251,25
Pay Back PeriodPay Back Period 3,293,29 YearYear
Financial Analysis
1515
CPO/PKO
FOOD
NUTRACEUTICAL (β-carotene, tocopherol)
SURFACTANT
PHARMACEUTICAL
COSMETIC
BIODIESEL/LUBRICANT
BIOPOLYMER
CPO & PKO DERIVATES
1616
PALM OIL BYPRODUCT, BIOMASS AND WASTE UTILIZATION PALM OIL BYPRODUCT, BIOMASS AND WASTE UTILIZATION (PLANTATION & CPO MILL)(PLANTATION & CPO MILL)
Waste Water
Biogas
Land Application
Plantation
Fresh Fruit Bunch
Oil Palm Mill
Energy
Public
Fiber
OrganicFertilizer
Compost
Empty Fruit Bunch
Shell
MaterialActive Carbon
Energy
Energy
Material
Electrical Energy
Steam Turbine
BoilerSteam Energy
Feed
Biomass
Direct Combustion
Gasification
Microbial Act
Physical/Chemical Process
Biomass : Shafts, roots, flowers, empty fruit bunches
1717
PALM OIL BYPRODUCT UTILIZATION PALM OIL BYPRODUCT UTILIZATION (CPO MILL)(CPO MILL)
Waste Water
Biogas
Land Application
Plantation
Fresh Fruit Bunch
Palm Oil Mill
Energy
Public
Fiber
Organic Fertilizer
Compost
Shell
MaterialActive Carbon
Energy
Energy
Material
Electrical Energy
Steam Turbine
BoilerSteam Energy
Feed
Empty Fruit Bunch
1818
Electric Power
Gasification
Indirect Liquefaction
Pyrolysis
Direct Liquefaction
Synthesis Gas
Fuel Gas
Liquid FuelChemical Feedstocks
Anaerobic Digestion
Aerobic Digestion
Hydrolysis Fermentation
Methane
Compost
Ethanol
BIOMASS
Direct Combustion
Thermochemical Conversion
Biochemical Conversion
BIOMASS CONVERSIONBIOMASS CONVERSION
1919
DEMO-PLANT OF THE BIOMASS CATALYTIC CFB DEMO-PLANT OF THE BIOMASS CATALYTIC CFB (Circulating Fluidized Bed) GASIFICATION SYSTEM(Circulating Fluidized Bed) GASIFICATION SYSTEM
3D - GASIFICATION PLANT
GASIFICATION PLANT
Gasifier
Regenerator
Cyclone
Biomass Hopper
Heat Recovery Steam Generator
Bag Filter
FD Fan
Product gas to engine
2020
BIOMASS AND WASTE WATER UTILIZATIONBIOMASS AND WASTE WATER UTILIZATION
Compost
Biomass
Land Application
Waste Water
Direct Combustion
Biogas
Physical/Chemical Process
Microbial Act
Gasification
Industrial Materials
Energy
Biomass : Shafts, roots, flowers, empty fruit bunches
2121
BIOGAS FROM ANAEROBIC PROCESS BIOGAS FROM ANAEROBIC PROCESS OF WASTE WATEROF WASTE WATER
Organic Residue
Hydrolytic and Fermentative
Soulble Acids,Alcohols,and Neutral Compounds
Acid-forming Bacteria
Methane-forming Bacteria
CH4 CO, 2 H, 2S
Acetate
Acetate
Acetate
H & CO
H
1 TONNES FFB
17 M3 BIOGAS
2222
RATE OF BIOGAS PRODUCTION RATE OF BIOGAS PRODUCTION ANAEROBIC PROCESS ANAEROBIC PROCESS
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
20 30 40 50 60Temperature ℃( )
Bai
oga
s pr
odu
cti
on
ml/
L/da
y(
)midle temperature
high temperature
2323
WASTE WATER UTILIZATIONWASTE WATER UTILIZATION
ParametParameterer
AveragAveragee
Standard Standard KLHKLH**
pHpH 4.24.2 6-96-9
BOD BOD (mg/l)(mg/l) 25.00025.000 100100
COD COD (mg/l)(mg/l) 50.00050.000 350350
TS (mg/l)TS (mg/l) 40.00040.000 250250
SS (mg/l)SS (mg/l) 18.00018.000 2525
Lemak Lemak (mg/l)(mg/l) 6.0006.000 ??
(SOURCE : DIDIEK GOENADI, LRPI:2005)
* Ministry For Environment of Indonesia
2424
PALM COMPLEX MODELPALM COMPLEX MODEL
CPO MILL
PLANTATION
MAIN PRODUCTCPO & PKO
BYPRODUCT
BIOMASS
COMPOSTMATERIALFOOD LUBRICANT COSMETIC & PHARMACEUTICAL
SURFACTANT
MARKET
ENERGY
2525
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