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