PERUNDING AME – Consulting Engineers 1

AN ENVIRONMENTAL CONTROL PLAN (ECP)

By Noel Wambeck April 1999.

FOR THE PROPOSED OIL PALM MILL WITH AN INTEGRATED EFFLUENT TREATMENT AND
DISPOSAL SYSTEM, AIR POLLUTION AND SOLID WASTE DISPOSAL SYSTEM.

01. INTRODUCTION.
The proposed Environmental Control Plan (ECP) will exploit every practical avenue to
provide a complete effective system for Effluent treatment, solid waste disposal, air pollution
control and minimising of the environmental impact, to the requirements and expectations of
DOE, local authorities and inhabitant indemnity.

The Department of Environment has set a target for Oil palm mills to achieve 100 percent
compliance by the year 2000 in terms of meeting emission and effluent discharge standards,
which are :

• Environmental Quality ( Licensing ) regulations 1977.

• Environmental Quality ( Prescribed Premises) (Crude Palm Oil ) Regulations 1977

(Amendment) 1982.

• Environmental Quality ( Clean Air ) Regulations 1978.

The overall objective of this project report is to determine and advise the client on the
following :

1 Proposed project needs in terms of design, cost, capacity, manpower requirements and
project schedule.

2 Selection of the Oil Palm Mill complex location.

3 Provide detail design and specification, supervision, commissioning, training of

personnel and guarantee performance for the proposed project.

4 Care in the implementation of the project, and not to endanger the environment by
providing the proper process, system and method for the treatment of effluent for 100 %
land application, solid waste disposal and the control of noise and air pollution.
PERUNDING AME – Consulting Engineers 2

02. PROJECT SALIENT DATA.

The following salient data is used in the design calculations:-

2.1 Milling capacity ( MT / FFB per hour. ) : 30 mt per hour

720 mt FFB per day

2.2 Amount of Empty Bunches for disposal (mt / hr.) : 7. 5 mt per hour
Based on the ratio of 25% Empty bunches to FFB 180 mt per day

Empty bunch decomposing period : 90 days

Area required for mulching ( 2333m3 / Ha ) : 26 Ha

2.3 Ratio of raw effluent (POME) to FFB : 60 %

2.4 B.O.D. level of raw effluent (POME) : 25,000 mg/l

2.5 Processing hours – based on peak operation : 24 hours.

2.6 Average flow rate of effluent (POME ) : 18 m3 / hr

or 432 m3 / day
2.7 Effluent ( waste water ) treatment system :
1 No. Sterilizer condensate oil recovery tank : 120 m3
1 No. Sludge oil recovery tank : 120 m3
2 Nos Fat pits : 20m3 volume : 40 m3
2 Nos Cooling Ponds : 256m3 each : 461m3 / hr HRT 2.13 days
1 No. Mixing Pond 461m3 : 461m3/ hr HRT 1.07 days
3 Nos Digesting Tanks : 3720m3 each : 11,160 m3 HRT 25.8 days
4 Nos Aeration reactor : 2000m3 each : 8000 m3 HRT 4 days
1 No. Sludge drying bed : 6 x 30 m : 180 m2
1 No. Sludge Clarifier : 225.6.m3 : 225.6m3 HRT 12.5 hr
1 No. Treated effluent holding tank

B.O.D. level of Final discharge : < 20 mg/l

Total BOD reduction : 99.9 %

2.10 Proposed site area : 122 ha

Area allocated for Oil palm mill complex : 12 ha

Percolation Rate of liquid Effluent on proposed land : 560m3 / day / ha

Area allocated for field / Land disposal of final effluent : 69 ha

in trenches / furrows ( based on 90 days cycle )

2.11 Boiler Gas Volume : 30 m3/ s

2.13 Dust load : 4000mg/ NM3 max.

2.14 Boiler Air Emission : < 0.4g / NM3

PERUNDING AME – Consulting Engineers 3

03. SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION

Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling
process systems, in -plant process control, equipment maintenance and good house-keeping.

The solid waste or by-products in the oil palm milling process, consist of :

• Empty bunches
• Shell and fibers
• Decanted solids
• Sludge centrifuge solids
• Boiler ash
• De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered
dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold
as produces.

The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill.

Waste water from the sterilizer condensate, clarification effluent and hydro-cyclone or claybath
discharges are sufficiently contaminated and require treatment.

Some of the sources waste water discharged from the steam turbine condensate / cooling system and
boiler blow down are relatively clean and can be put to good use in the process suc h as for the dilution
system, screw press, oil gutter spraying and for the factory floor cleaning requirements.

The liquid effluent total quantity of 0.6 m≥ to 1m≥ per ton of FFB between the generating sources
being as follows :

• Sterilizer condensate
• Calrification station
• Hydrocyclone / Claybath.
• Other waste water

The table below presents the typical physical and chemical properties of raw effluent from Oil palm
milling process.

PARAMETER MEAN

pH 4.1
BOD 25,000
COD 53,630
Total Solids 43,635
Suspended Solids 19,020
Volatile Solids 36,515
Ammoniacal Nitrogen 35
Total Nitrogen 770
Oil and Grease 8,370

* All values except pH are in milligrams per liter ( mg / L) Source : PORIM

PERUNDING AME – Consulting Engineers 4

04. POLLUTION CONTROL SYSTEM.

The proposed Pollution control and treatment systems are :

4.1 THE DISPOSAL OF EMPTY BUNCH.

4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM

4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM.

4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION.

4.5 CONTROL OF AIR EMISSIONS.

The brief process description of the above systems are as follows:

4.1 THE DISPOSAL OF EMPTY BUNCH.

Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content of
approximately 55 – 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch.

The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but are
rich in major nutrients and contain reasonable amounts of trace elements. They have a value when
returned to the field as mulch for the enrichment of soil.

The use of empty bunch for field application as mulching material is preferred by the client, therefore
we shall confine to this method of disposal of empty bunch for the proposed oil palm plantation.

The land application .mulching system is said to have a cost savings of RM 250 per ha annually in
place of fertiliser supplement.

In Perak state, several estates have this system of land application of empty bunch mulching, including
Seri Pelangi, Nova Scotia, Jendarata Estate, since 1973 on a commercial scale.

Other mills that used the same method of disposal are; Ulu Basir, UIE, Southern Perak, Changkat
Chermin, Topaz Emas, Foong Lee etc

To do this, adequate hopper and conveyor system will be provided at the oil palm mill site for storage
and an arrangement of tractor & trailer with a capacity of 5 -10 mt EFB shall be deployed for the
transportation of the treated empty bunches ( de-watered ) to the field for disposal.

On arrival at the estate, the train of two or more trailers are parked on the road adjacent to the inter row
to be mulched and with the aid of the extended draw-bar, the trailers are unhitched one from the other.

The trailers are towed one at a time into the inter rows and tipped while slowly moving forward.

The empty trailers are then hitched back one to the other by lifting with the tractor draw-bar and pins
put into position, they than return to the mill to repeat the process.
PERUNDING AME – Consulting Engineers 5

The drainage pattern in most fields is four palm rows to a drain, to ensure that all palms benefit from
mulching, the empty bunches are applied in the avenue between row 2 and 3, and between palm points
in the two outer drain side rows ( see the diagram of the Placement of empty bunches in the appendix.)

In the latter, the side-tipping trailers are particularly useful. Manual labour is used to make minor
improvements where leveling may be required.

The rate of application ranges between 75 to 100 tons empty bunches per hectare.

In conclusion, bunch mulching of oil palms on a commercial scale is recommended as a

viable proposition in plantation where the terrain and ground conditions allow
mechanisation of the operation.

4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM

( FOR THE PRODUCTION OF SOLID WASTE SLUDGE ( POME ) AS ANIMAL FEED OR FERTILISER. )

The Decanter – Drier integrated system reduces the volume and handling of oil palm mill effluent
discharge of about 75% of the total BOD load discharge from the mill.

The system also provide a means of a dust collecting system for the boiler flue gas with the advantage
of being able to produce an added value by product of dried sludge ( POME ) for animal feed or
fertiliser, resulting in better returns on investment of the project.

The source of solid waste effluent are :

1. Decanter solids
2. Steriliser condensate sludge
3. Clarification station sludge
4. Boiler ash
5. De-sludging of the effluent treatment system
6. De-sludging of all process tanks

The use of the Decanter in the oil clarification station for the removal of solid matter, reduces the load
on the separator and static clarification settling tank by about 50 – 75% while there is not change in the
load on the other machinery of the clarification station process.

Process dried sludge has certain properties:

• Releases nutrients slowly

• It supplies trace elements
• And it improves water retention.

The system proposed has been developed and in operation over 20 years at United Plantations Mills,
Keck Seng and several other mills in Malaysia and Indonesia.
PERUNDING AME – Consulting Engineers 6

The proposed system details are as follows :

A. Multi cyclone separator.

The multi cyclone will remove coarse sand and other solid matters with a particle size of more than 50
microns or about 50% of the solid matter from the crude oil.

B. The Decanter system.

The decanter will remove approximately 90% of all suspended solids from the crude oil.

C. Rotary Drum drier.

Solid sludge is conveyed by the screw conveyor and fed to the Rotary Drum Drier located close to the
boiler house for heating by the Boiler flue gas.

The rotary drum drier in which the flue gas from the boiler, is in direct contact with the wet solids
discharged from the decanter, multi cyclone and oil pit – effluent recovery system.

Flow of the flue gas and solids is con-current. The flue gas is tapped from the chimney above the
boiler fan.

The ducting size would be the same size of the chimney and the portion of the chimney above the
ducting is closed with a damper for flue gas control.

The diamension of the rotary drum drier is 2 meter in diameter and about 15 meter in length.

D. Dried sludge clarification screen.

The dried sludge material with a moisture content of 10% is discharged at the end of the rotary drum
drier and conveyed by a screw conveyor and fed to the vibrating screen.

A circular vibrating screen will screen the dust and sludge grains before the mixing and packing in
polybags for storage as the finished product and sold to buyer.

The product POME ( Palm Oil Mill Effluent Dried sludge )

The best prospects for POME as an animal feed because of its ability to substitute some of the
expensive imported components of feed meals and as a fertiliser, POME is a good source of major and
minor nutrients.

Commercial value of POME fertiliser is about RM 500 per ton and sold to plantations, flower gardens,
golf club application to turf etc.

A comprehensive analysis of dried sludge is given in the table below:

% % p.p.m.
Moisture 5 – 15 N 1.8 – 2.3 B 20
Ash 15 – 22 P 0.3 – 0.4 Cu 20 – 50
Silica 7 – 10 K 2.5 – 3.2 Fe 3000-5000
Ether extract 11 – 13 Mg 0.6 – 0.8 Mn 50 – 70
Crude Fibre 11 – 14 Ca 0.6 – 0.8 Zn 20 – 100
Crude Protein 11 – 13
PERUNDING AME – Consulting Engineers 7

In conclusion, we can say that dried sludge or POME improves the water availability,
carbon and nitrogen content, a provider for microbial activities in soil and a useful
source of plant nutrients for crops grown on normal or degraded land.

An added attraction of the system that is of growing importance, is the reduction in air
pollution brought about by scrubbing of the boiler flue gas in the drier and finally its
yields an income as waste by-product.

4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM.

The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD)
which makes it objectionable to fish life when introduced in relatively large quantities in
waterways and rivers.

The effluent treatment system developed for use in this project shall be of a modern biological
system, characterised by the anaerobic and aerobic process phases.

The total effluent from the proposed Oil palm mill process is approximately 0.6 tons per ton ffb. which
is made up of :

1. Sterilizer condensate
2. Classification station dicharge of effluent
3. Hydrocyclone / Claybath waste water
4. Boiler blow down.
5. Wash water, make up the balance.

The proposed Anaerobic & Aerobic effluent treatment system, shall be located within the oil palm mill
complex, that will require an area of approximately 100 m x 100m ( 1 ha ) and will consist of :

• Sterilizer and Sludge oil recovery tank

• Fat trap pits
• Compressed air flotation unit.
• Cooling & Mixing tanks
• Anaerobic digesting tanks
• Aeration reactors
• Solids removal clarifer
• Effluent metering.
• Drying bed.
• Final effluent holding tank
• Monitoring & control system
• Pumps and Air compressor
• Inter-connecting piping, valves and fittings.

A schematic flow diagram and system calculations are enclosed in the appendix.
PERUNDING AME – Consulting Engineers 8

The system will be monitored on site for pH, volatile fatty acids (VFA), total alkalinity (TA) and
solids contents whereas the more complex tests for BOD, COD, ammoniacal nitrogen (AN) and total
organic nitrogen (TKN) analysis will be sent out to reputable laboratory for samples test.

The proposed effluent treatment system shall be procured from experience environmental control
equipment and system vendor who will guarantee its performance.

Full advantage is to be made of the “ decanter “ and the “ decanter solids “ dryer, design to dry all of
the wet solid sludge removed from the system.

To this end part of the sludge outlet water is to be used at the screwpress, in place of the existing
dilution water, to assist the transport of the crude oil to the clarification plant.

THE PROCESS
The effluent treatment system will include two main parts, the anaerobic section and aerobic
stabilisation process before the final discharge of treated palm oil mill effluent onto the plantation for
palm tree irrigation.

The condensate discharge from the sterilizers is pumped to the post static clarifier an oil recovery
system tank.

The oil skimmers removes the highly contaminated oil from both the clarifier and sludge decanter tank
which is isolated in a special drumming holding tank.

The sludge will than pass through a CAF unit for the removal of disolved oils, grease by flotation
process etc,… before being fed to the cooling pond.

Every precaution is to be taken to ensure that this oil cannot and does not contaminate the crude oil
system.

The objective is to reduce the loading of the effluent treatment system by the removal of the oil and
solid matter in sterilizer condensate at an early stage.

The deoiled sterilizer condensate is then discharged in to its own isolated effluent collection pit
And overflow to the effluent treatment sys tem.

The sludge slurry which are drained from the static clarifier and sludge decanter tank are
discharged to the drying bed or conveyed to the rotary sludge dryer for the drying process.

The anaerobic phase is favoured by higher temperature and the absence of air.

The influent from the sterilizer sludge pit and the clarification pit is to be pumped to the cooling pond
and than to the mixing pond.

The anaerobic process start to take place in the first pond and end at the digester tanks.

There the complex organic materials are first solubilized by the extra cellular enzymes and then
converted to volatile acids by acid producing bacteria.
PERUNDING AME – Consulting Engineers 9

In the last methane fermentation phase the volatile acids are transformed to methane and carbon
dioxide.

The process is to be accelerated by the circulation of the bacteria laden sludge into the mixing pond of
the material from the last digester tank.

The acidification process will have an HRT of 1 day. Effluent from the mixing pond is pumped from
the collecting sump and into the digesters with a total HRT of more than 20 days.

The discharge from the overflow of the final anaerobic tank is to be discharge into an open pit and
pumped into the aerobic reactor tanks for the extended aeration process equipped with over powered
mechanical aerators.

The overflow of the aerobic reactor tank, operating in tandem with a total HRT of 4 days will be
pumped to the clarifier tank for the removal of solids.

The sludge scum is to be held back and removed from the ample sized “sludge clarification tank”.

Sludge accumulated at the bottom of the clarifier, and drying bed, are to be removed by the auto
programmed system provided for the sludge removal process.

The separated sludge cake can be dried in rotary dryer and used as plant nutrient in compound form as
a by product.

The treated effluent is now pumped to the final effluent holding tank.

A finish effluent holding tank will hold the effluent waste water with a BOD of 20 ppm for
displacement into furrows in the plantation disposal area.

The system is to be stable and is to be capable of with standing reasonable shock loads.

The efficiency of the system is facilitated by a monitoring and programmable control system design
which requires only simple maintenance and operational skills.

4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION.

The recycling of POME in plantations is now widely accepted as an economically viable and
environmentally acceptable waste management technique.

Treated Effluent are pumped or discharged by gravity to the pre-selected area as a good source of plant
nutrients and a value added ( RM 350 per ha / year ) cost effective organic fertilizer.

The disposal of treated effluent for land application require an area of approximately 69 hectares in the
plantation, have been marked in the vicinity of the proposed oil palm mill to receive the effluent in
loaded furrows.

A typical furrow layout is shown in the report drawing section.

Field drains on the sides of each plot which act as trenches to prevent poaching.
PERUNDING AME – Consulting Engineers 10

a. Methods of Land Application.

The percolation through furrows or trenches method will be used in the land application of treated
effluent of approximately 560m3 / day / ha for the given volume at an application cycle of mor e than
90 days, based on experience.

b. Factors for consideration.

The following factors effect the rate of application.

• Soil characteristics such as porosity, water table, acidity of soil;
• Characteristics of effluent, such as concentration of large solids;
• Age of oil palms;
• Vegetation in between the oil palms;
Over application of the effluent must be avoided which may result in anaerobic conditions in the soil by
formation of an impervious coat of organic matter on the soil surface.

c. The percolation through furrows or trenches system.

Waste Water Effluent is pumped or discharged by gravity to the high points of the pre-selected area and
allowed to drain down the slopes in furrows or trenches shown in the appendix “ Typical Furrow
layout”.

The velocity of flow is given as a steady infiltration rate of 7 – 11 cm per hour, slow enough to enable
percolation into the soil and also it prevents erosion.

An area of approximately 110 hectares have been marked and allocated in the vicinity of the proposed
oil palm mill, shown in the “ Soil suitability for land application of Palm Oil Mill Effluent Survey
Report” enclosed.

The furrows or trenches are about 90 cm / 60 width x 75 cm depth shown in the appendix and survey
report.

Field drains of each plot, which act as pits to prevent poaching and used as silt traps to contain
sediments transported by surface erosion.

d. Effects of land application.

Yields of oil palm increases with the use of oil palm mill effluent. The optimum rate of application is
approximately 40 cm rainfall per year.

The nutrient value of the soil also shows improvements with land application, especially the nitrogen,
phosphorus, potassium and magnesium values.

The effect on underground water and surface drainage, are negligible.

PERUNDING AME – Consulting Engineers 11

4.5 CONTROL OF AIR EMISSIONS.

The Environmental quality ( clean air ) regulation 1978 stipulate the permitted level of solids
concentration in gases emitted from solid waste thermal plants to be not more than 0.4 g per
cubit meter.

Air emissions from oil palm mills are from the boilers and incinerators, being mainly gases with
particulates such as tar and soot droplets of 20 – 100 microns and a dust load of about 3000 to 4000
mg. / NM3.

Incomplete combustion of the boiler and incinerator produces dark smoke resulting from burning of a
mixture of solid waste fuel such as shell, fibre and some times empty bunches.

A good design and properly rated boiler capacity with a closed loop control over the fuel feed rate and
air supply will ensure steady state combustion in tandem with steam demand.

The introduction of the proposed system will alter the situation whereby the thermal plant such as the
waste fuel boiler shall emit clean smoke in accordance to the DOE standard requirements.

The scrubber system.

Flue gas from the boiler furnace with a temperature of approximately 288 deg. C flow through the
ducting to the scrubber.

Water is sprayed from the top of the scrubber, through a manifold and then mixed with the flue gas and
dust particles where the proc ess of separation of the particles, gas and water droplets take placed.

The spray water of 10 m3 per hour used in this system are from the steam turbine cooling system and
heat exchange steam condensiate waste water.

The cooled clean gas is conveyed by the ID fan that blows the exhausted gas to the chimney

Slurry from the separator is collected in a seal tank via a trap sump and pump to the effluent treatment
plant.

The scrubber system consist of :

• Scrubber unit
• Fan
• Moisture separator
• Pump
• Inter-connecting piping, valves, fittings and duct works.
• Control , Instrumentation & wiring.

The above system vendor guarantee an emission at the chimney outlet of less than 400 mg./ NM3 and
in accordance to the DOE allowed standard.
 PERUNDING AME – Consulting Engineers 12

5.0 PROJECT COST.

The project cost of establishing the proposed mill with a capacity of 30 mt FFB per hour is estimated
at the total cost of approximately RM 30 million.

This amount is made up of RM 25.6 million for the conventional oil palm mill and the additional
investment of RM 4.4 million or 17.19% more for the systems required for the proposed
Environmental Control Plan.

The expenditure is spread over the mill constructional period of two years.

The summary of the above costs are as follows :

PACKAGE DETAILS INVESTMENT ADDITIONAL

1. PRELIMINARIES 330,000
2. SITE FACILITIES 270,000
3. EARTH WORKS 1,400,000 400,000
4. QUARTERS BUILDING WORKS 2,800,000
5. RAW WATER SUPPLY AND TREATMENT 800,000
6. CIVIL & STRUCTURE WORKS 7,500,000
7. MECHANICAL & PI 10,500,000 1,700,000
8. STORAGE TANK FARM 600,000
9. ELECTRICAL WORKS 1,400,000 300,000
10. EFFLUENT TREATMENT PLANT 2,000,000

25,600,000 4,400,000

TOTAL PROJECT COST in RM 30,000,000

Additional Investment for ECP in % is approximately : 17.19 %

Preliminary estimates can vary extensively depending on terrain, type of soil, accessibility, selection of
quality of equipment and design factors applied.

The above estimate have taken into consideration of the following :

a). Best applied technology, innovation and development for a modern oil palm mill.

b). Proven design of machinery, systems and plant layouts.

c) The site for locating the proposed oil palm mill has been selected on the basis of
substantial cost savings in transportation, as being one of the factors for its selection.

“ Our aim is to help shape our common future and to save us from being submerged in sludge.”

 April 1999 Noel Wambeck

POTENTIAL HAZARDS AND CONTROL PLAN.

The potential hazards which could affect the public water supply and the proposed control plan in
place, are as follows :

POTENTIAL HAZARDS. CONTROL PLAN.

1. Process wastewater 1. Runs into process drains, fat pit collecting sump,
effluent oil recovery and solid removal system
before discharge to effluent pond system.

2. System failure of mill during operation 2. Shut down of operation for major problems or
effect repairs immediately of equipment and plant
for minor repairs, all runoffs into process drains.

3. Wash water contaminated with oil. 3. Runs into process drains, the Fat pit collecting
sumps and effluent treatment.

4. Oil tanks leakage, spillage during loading into oil 4. Runs into process drains and into collecting sump
Tankers. for recycling back to process.

5. Fuel tanks spillage during unloading and pipe line 5. Contained in bund storage area.
Leakage

6. Lubrication oils & Chemicals spillage 6. Contained in bund storage area

7. Boiler blow down waste water 7. Runs into dedicated process drains

8. Rain water flooding. 8. Runs into dedicated storm drains.

9. Oils and sludge in the sump 9. Oil is skimmed and pumped into drums for sale,
whereas the treated sludge and sterilizer
Fat pit collecting sumps. condensate waste water will be treated in the
Ex- Oil room waste water, Sterilizer condensate effluent treatment system and than discharged of
water, Hydrocyclone / Claybath and wash water. the effluent to the plantation with BOD of 20 ppm.

Perunding AME / 22 nd. February 1999.

OIL PALM MILL ENVIRONMENT CONTROL PLAN ( EPC System )

WASTE MATERIAL REDUCTION FINAL TREATMENT & DISPOSAL

Present system
CONDENSATE
SLUDGE TANK
STERILISER CONTROL Anaerobic
CONDENSATE STATIC SEPARATION & Aerobic (CAA)system TREATED
OIL RECOVERY EFFLUENT

Liquid phase to EFFLUENT to Field

Effluent ponds

CLARIFICATION DECANTERED
STATION WASTE SLUDGE SLUDGE Drying
System to produce Bag POME
WATER
Liquid phase to Fertilizer products
CAA system

POTASH production
EMPTY BUNCH INCINERATOR POTASH
FIELD DISPOSAL
FROM
THRESHING STORAGE HOPPERS Dewatered bunch for oil
STATION recovery and COGEN power
DEWATERING production. OIL and POWER
PROCESS
FIBRE products FIBRE products

MULTI CYCLONE
CLEAN
WATER TUBE DUST SEPARATOR Full combustion for FLUE GAS
BOILER Reduction of dust particles
Subject to shock Discharge of air to less than 0.2 mg / m3 in
loads / unstable polluting dust to flue gas
combustion atmosphere

INSTALL SOUND DAMPERS

PROCESS LINE TO HIGH SPEED MACHINERY.
& POWER ROOM SOUND CANOPY MAINTAINED EQUIPMENT NOISE
MACHINERY PARTITIONED CONTROL
NOISE Reduce to 50 dB / m sound
ROOM
Limits

ECONOMICS OF WASTE BUT WASTE NOT OF USEFUL VALUE ADDED PRODUCTS

ZERO HAZARDS
& AIR TREATMENT DISPOSAL &
LIQUID PRODUCTION
SOLID WASTE POLLUTION & CONTROL
EFFLUENT HAVE VALUE
ADDED PRODUCTS

© Noel Wambeck / 8th December 98.

PROPOSED PLACEMENT AVENUE FOR EMPTY BUNCHES, FRONDS AND
TREATED EFFLUENT FOR LAND APPLICATION.
 PRESS STATION CLARIFICATION STATION BOILER HOUSE

STERILIZED
FRUITLETS

WET SLUDGE FOR

DRYING PROCESS

BAGGING OF
DRIED POME

POME SLUDGE PROCESS WITH THE DECANTER & DRYER – SCHEMATIC FLOW DIAGRAM
 HOLDING / DISTRIBUTING
FURROW FURROW PVC OVERFLOW PIPE

CONTIGENCY
FURROW

EFFLUENT PIPE LINE –

PUMPED FROM MILL

ESTATE RING ROAD FOR INSPECTION PURPOSE

Perunding AME / 20th April 99 / NW. TYPICAL FURROW LAYOUT

 OIL PALM TREE MATRIX OIL PALM COMPONENTS, BIOMASS AND ANALYSIS

by Noel Wambeck 6/12/00 11:46

UNIT MEASURE WEIGHT PERCENTAGE

BASIC DATA
1 Type of Palm tree Tenera ( D x P )
2 Planting density Number of trees per hectare Trees per hectare 143
3 Growth of fronds per year New leaves per year Nr. Of Fronds 21 - 25
4 Tree growth rate per year Vertical trunk height mm / year 1000
5 Inflorescence full production at every days per cycle 15
6 Production of FFB per year number of fruit bunch Nr / year 300
7 Weight of Fresh fruit bunch (FFB) average weight kg 20
8 Fruitlets in each bunch Individual fruitlet Nr 1500
9 Weight of each fruitlet Individual fruitlet grammes 8 to 10
10 FFB yield per year average weight per hectare in a year mt / year 25
11 Crude oil yield per year average weight per hectare in a year mt / year 6
12 Palm Kernel yield per year average weight per hectare in a year mt / year 1.1

13 BIOMASS
13.1 Biomass of fronds pruned annually average weight per year / hectare mt / year / ha 10
13.2 Biomass of Fibre average weight per mt FFB kg 120
13.3 Biomass of Shell average weight per mt FFB kg 80
13.4 Biomass of Empty bunch average weight per mt FFB kg 240
13.5 Moisture in bunch average weight per mt FFB kg 200
13.6 Solid matter in bunch average weight per mt FFB kg 40
13.7 Biomass of spears average dry weight of spears / palm kg / palm / dry 9.4
13.8 Biomass of cabbage average dry weight of cabbage / palm kg / palm / dry 4.5
13.9 Biomass of inflorescences average dry weight of inflorescences / palm kg / palm / dry 6.3
13.10 Biomass of Leaflets ( average 40 fronds ) average dry weight of leaflets / palm kg / palm / dry 58 9%
13.11 Biomass of Rachies ( average 40 fronds) average dry weight of Rachies / palm kg / palm / dry 118 19%
13.12 Biomass of frond bases ( average 40 fronds) average dry weight of frond bases / palm kg / palm / dry 130 21%
13.13 Biomass of Trunk ( 6-9 m length ) average dry weight of Trunk / palm kg / palm / dry 302 48%
13.14 Biomass of matured palm tree in total weight average fresh weight of palm tree 6-9 m kg / palm tree 2200

14 ENERGY
14.1 Energy value for Oil palm products Annual energy values - INPUT GJ / ha / year 19.2
Annual energy values - OUTPUT GJ / ha / year 182.1
Energy values Ratio 9.5

14.2 Energy consumption in oil palm plantation INPUT

Fertilizers GJ / ha / year 11.2
Pesticides, herbicides, rat baits GJ / ha / year 0.8
Machinery GJ / ha / year 5.14
other GJ / ha / year 2.06
14.3 Methane yield of kg mill effluent dry matter average yield of methane is litres per kg dry matter l / kg 230

14.4 Gas liberated by anaerobic digester contain methane percentage 60% l / kg 230
carbon dioxide percntage 35% l / kg 135
other gas percentage 5% l / kg 19
15 BULK DENSITIES
15.1 Air average weight in kg per m3 kg / m3 1.177
15.2 Ash average weight in mt per m3 mt / m3 0.437
15.3 Bunch same same 0.550
15.4 Cracked mixture same same 0.653
15.5 Crude Palm Oil same same 0.890
15.6 Diluted crude oil same same 0.900
15.7 Fibre same same 0.350
15.8 Fresh Fruit Bunch same same 0.480
15.9 Fruitlets same same 0.680
15.10 Palm Kernel Oil same same 0.890
15.11 Palm Nuts same same 0.653
15.12 Palm Olein same same 0.900
15.13 Palm Stearin same same 0.880
15.14 Press expelled cake same same 0.650
15.15 Pure water without air at 30degC same same 0.990
15.16 Shell same same 0.750
15.17 Sludge same same 0.900
15.18 Sterilized Fruit same same 0.660
15.19 Vegetable oils same same 0.950
15.20 Water at 4 deg.C max same same 1
16 AIR ABSORPTION / EMISSIONS OF PALM TREE
16.1 Absorption of Carbon Dioxide tonnes of carbon dioxide per hectare tonnes
16.2 Carbon Dioxide emission to produce kw displacement of fossal fuel / tons carbon dioxide per kw tonnes 5
16.3 Oxygen emmissions per hectare tonnes of oxygen per hectare tonnes
17 Soil enrichment contribution
17.1 Carbon contribution of root biomass at replanting
contributes carbon per hectare at replanting mt / ha 8
17.2 Nutrient stocks of above ground biomass N kg / ha 577
for replanting cycle P kg / ha 50
K kg / ha 1255
Mg kg / ha 141
Ca kg / ha 258

17.3 POME application 3 rounds a year or equivalent to twice rate of Nitrogen kg N/ ha/ year 650
17.4 Properties of raw effluent (POME) pH mean 4.1
BOD mg / Liter 25,000
COD mg / Liter 53,630
Total solids mg / Liter 43,635
Suspended solids mg / Liter 19,020
Volatile solids mg / Liter 36,515
Ammoniacal Nitrogen mg / Liter 35
Total Nitrogen mg / Liter 770
Oil & Grease mg / Liter 8,370
17.5 Analysis of dried sludge (POME) Moisture 5 - 15 % N 1.8 - 2.3 % B 20 ppm
Ash 15 - 22 % P 0.3 - 0.4 % Cu 20-50 ppm
Silica 7 - 10 % K 2.5 - 3.2 % Fe 3000-5000 ppm
Ether extract 11 - 13 % Mg 0.6 - 0.8 % Mn 50-70 ppm
Crude fibre 11 - 14 % Ca 0.6 - 0.8 % Zn 20-100 ppm
Crude protein 11 - 13 %