1. PRESENTATION OUTLINE

Transcription

1 ZERO WASTE TECHNOLOGY FOR PALM OIL MILLS: LATEST INNOVATION AND HOLISTIC COMPOSTING SYSTEM (POMEDfree ) DR. HJ. ZULKIFLI AB. RAHMAN Malaysian Palm Oil Board CH00 HUAN BOON Genting Plantations Bhd M P O B 1. PRESENTATION OUTLINE 1. CONCEPT OF POMEDfree TECHNOLOGY 2. DEVELOPMENT OF TECHNOLOGY 3. KEY BENEFITS OF THE TECHNOLOGY TO THE INDUSTRY 4. POMEDfree PLANT PERFORMANCE OVERVIEW (GJOM) 5. ECONOMICS 6. CONCLUSION 7. WAY FORWARD 2 1

2 2. PRESENTATION OUTLINE (Choo Huan Boon) 1. INTRODUCTION TO ZERO WASTE TECHNOLOGY 2. CHALLENGES IN ACHIEVING ZERO WASTE TECHNOLOGY 3. OPERATION & PERFORMANCE EXPERIENCES 4. FIELD APPLICATION CONCEPT OF TECHNOLOGY -ZERO POME DISCHARGE- MAXIMIZE Water Out MINIMIZE POME POMEDfree PLANT Controlled / reduced POME Production Prevent Rain Water Thermophilic & Bio Control Inoculants High microbial activity Zero Discharge 2

3 CONCEPT OF TECHNOLOGY A. Minimize POME production 1. Continuous sterilization 2. Zero dilution process 3. 5 stage dry separation winnowing column 4. Reuse condensate for mill usage 5. Prevent excessive mill washing B. Maximize water evaporation 1. Using thermophilic temperature ( ºC) 2. Massive evaporation through mechanical turning of compost heap 3. Roofing to prevent rain water 4. Innovative blower system CONCEPT OF TECHNOLOGY -100% RECYCLING OF NUTRIENTS- MAXIMIZE Water Out From Mill 100% POME 100% SLUDGE Zero Discharge 100% EFB 3

4 POMEDfree Zero Waste Technology Flow Chart Flowchart of Genting Jambongan Palm Oil Mill Zero Waste Technology Mill Influent Conditioning Tanks Hydrolysis Tank Pumps 1/2 Buffer Tanks Leachate Pt 1 Air Blower 1 Windrow Building 1 Air Blowers 1 & 2 Windrow Building 2 Air Blower 2 Leachate Pt 2 Mixed EFB+Decant Slurry Input Mature Compost Output Pumps 3/4 Mixed EFB+Decanter Slurry Input Mature Compost Output 4

5 KEY BENEFITS OF POMEDfree TECHNOLOGY TO OIL PALM OIL INDUSTRY KEY BENEFITS OF POMEDfree TECHNOLOGY PROFIT ZERO POLLUTION DISEASE CONTROL SUSTAIN- ABILITY 100% Nutrients Recycling (All POME Evaporated Away) (Prevent Ganoderma Attack) (Sustainable Palm Oil Change World s Perception) 5

6 POMEDfree PLANT PERFORMANCE OVERVIEW (GJOM)

7

8 ECONOMICS 15 Nutrient Content Studies Nutrient content of POME Study 1 Study 2 Study 3 Study 4 Study 5 Study 6 Study 7 Study 8 Average N (kg/t POME) P (kg/t POME) K (kg/t POME) na 2.28 Mg (kg/t POME) Ca (kg/t POME) Nutrient content of EFB Study 1 Study 2 Study 3 Study 4 Study 5 Study 6 Study 7 Study 8 Average N (kg/t EFB) P (kg/t EFB) K (kg/t EFB) Mg (kg/t EFB) na 0.80 Ca (kg/t EFB) na na

9 Nutrient Content Analysis Nutrient per mt FFB* 30mt/hr mill 60mt/hr mill minimum maximum minimum maximum minimum maximum N (kg) , , , ,086 P (kg) ,172 58,662 52, ,324 K (kg) , , ,182 1,654,992 Mg (kg) , , , ,434 Ca (kg) ,498 87, , ,932 Total (kg) ,091 1,366,884 1,744,182 2,733,768 Nutrient Value Analysis Nutrient Price (RM/mt) per mt FFB* 30mt/hr mill 60mt/hr mill minimum maximum minimum maximum minimum maximum N (RM) 4, ,281 1,082,707 1,828,562 2,165,414 P (RM) 1, , ,960 95, ,921 K (RM) 2, ,300,019 2,281,131 2,600,038 4,562,261 Mg (RM) 2, , , , ,641 Ca (RM) ,478 76, , ,774 TOTAL VALUE (RM) ,548,989 3,951,506 5,097,979 7,903,012 * 1mt FFB produces 0.65mt POME and 0.23mt EFB 9

10 Cash Payback Period and ROI analysis 30mt/hr mill 60mt/hr mill POME (mt per FFB) Required Building Size (sq m) 7,200 10,000 13,000 14,300 20,000 25,700 Investment Cost (RM m) Recoverable Fertilizer Value Less operating cost Savings in fertilizer 2,548, ,000 1,936,989 5,097,979 1,224,000 3,873,979 Payback Period (years) Min* ROI (%) Min* 11.1% 9.5% 8.2% Recoverable Fertilizer Value Less operating cost Savings in fertilizer 3,951, , ,339, ,903,012 1,224,000 6,679,012 Payback Period (years) Max* ROI (%) Max* 19.1% 16.3% 14.2% CONCLUSION 20 10

11 CONCLUSION 1. The performance of the Jambongan POMEDfree Plant is outstanding, all the POME produced has been evaporated away. POMEDfree Technology has been proven with a full size plant in operation. 2. The biggest beneficiary is the environment. The savings in ecology cost from reduced air pollution and zero water pollution are very substantial. 21 CONCLUSION 3. Investment in the POMEDfree Technology is economically feasible. 4. Benefits to yield, disease control and sustainability are very significant. 5. In-house studies have shown that the use of biofertilizer can increase FFB yields by as much as 9% to 17%

12 WAY FORWARD 23 WAY FORWARD 1) Further collaboration R&D between MPOB and Nexus a) To determine whether POMEDfree can coexist with Biogas to recover nutrients and energy. b) To increase nutrients recovery from Mesocarp Fibre c) To conduct Research on Compost Application 24 12

13 POMEDfree Zero Waste Technology POMEdfree plant Shredded EFB Compost heap Turner machine in operation 13

14 14